Manual t.o.w. ford 300 tc (tig) tractor 2004.01

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Repair Manual Ford (TIG) TOW tractor 2004

Transcript of Manual t.o.w. ford 300 tc (tig) tractor 2004.01

Page 1: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 5: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 6: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 7: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 8: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 9: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 122: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 123: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70CORPORATION

FIGURE 1A

FINAL ASSEMBLY

DATE 2/1/96

4-4=EBRUARY1996 FIGURE1A

PAGE 1

Page 124: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

(3

TIGER

kTIGER

4-4FIGURE1A FINALASSEMBLY FEBRUARY1996PAGE2 FIGURE1A

Page 125: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

._v__________I__TI_/_C,T_ONR TIC-30 THROUGH 70

FIG.- TIGER FIGURENUMBER-- 1A UNITS

ITEM PART FINAL ASSEMBLY EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.1A- FINALASSEMBLY

1 FIGURE UNITASSEMBLY

2 FIGURE BODYANDFRAME

3 FIGURE FRONTSUSPENSION

4 FIGURE REARSUSPENSION

5 FIGURE TRANSMISSIONMOUNT6 FIGURE ENGINEMOUNT- FRONT

8 FIGURE STEERAXLE

9 FIGURE DRAGLINK

10 FIGURE STEERGEARASSEMBLY12 FIGURE STEERINGGEARMOUNTS

13 FIGURE FRONTWHEELANDTIRE

14 FIGURE REARWHEELANDTIRE

15 FIGURE ENGINE- CYLINDERBLOCKANDHEAD16 FIGURE ENGINE- GASKETS

17 FIGURE ENGINE- PISTONANDCONNECTINGRODS

18 FIGURE ENGINE- CAMSHAFTANDBEARINGS

19 FIGURE ENGINE- CRANKSHAFTANDACCESSORIES20 FIGURE ENGINE- VALVETRAIN

23 FIGURE ENGINE- COVERS

24 FIGURE ENGINE- OILPUMPANDOILPAN25 FIGURE ENGINE- OILFILTERASSEMBLY

26 FIGURE ENGINE- COOLINGSYSTEM-WATERPUMP

27 FIGURE ENGINE- MANIFOLDS

28 FIGURE ENGINE- EXHAUSTSYSTEM

29 FIGURE ENGINE- CARBURETORANDGOVERNOR

30 FIGURE ENGINE- FUELSYSTEM33 FIGURE ENGINE- AIRCLEANER

34 FIGURE ENGINE- EMISSIONCONTROLS

35 FIGURE ENGINE-IGNITIONSYSTEM

36 FIGURE ENGINE- ALTERNATORMOUNTING

37 FIGURE ENGINE- CHARGINGSYSTEM38 FIGURE ENGINE- STARTER

45 FIGURE FUELCELLANDACCESSORIES

46 FIGURE ACCELLERATORLINKAGE

47 FIGURE TORQUECONVERTER&FLYWHEEL48 "FIGURE TRANSMISSION-ASSEMBLY

49 FIGURE TRANSMISSION- GEARS& CLUTCHES50 FIGURE TRANSMISSION- CLUTCHES

51 FIGURE TRANSMISSION-INTERMEDIATESERVO& BAND

- Itemnotillustrated 4-4FEBRUARY1996 FIGURE1A

PAGE 3

Page 126: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

.SIg_oT_IT_NR TIG-30 THROUGH 70

FiG.- TIGER FIGURENUMBER-- 1A UNITS

ITEM PART FINALASSEMBLY EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.

IA- FINALASSEMBLY(CONT.)54 FIGURE TRANSMISSION- LINKAGE

55 FIGURE TRANSMISSION-SHIFTERASSEMBLY56 FIGURE TRANSMISSION- COOLINGSYSTEM

57 FIGURE PARKINGBRAKEASSEMBLY

58 FIGURE DRIVESHAFTASSEMBLY

59 FIGURE DRIVEAXLE

60 FIGURE REDUCTIONGEARBOX

61 FIGURE BRAKES- REARASSEMBLY62 FIGURE BRAKES- FRONTASSEMBLY

63 FIGURE BRAKES- LINES

64 FIGURE BRAKES- MASTERCYLINDER&VACUUMBOOSTER

65 FIGURE BRAKES- PEDALASSEMBLY

66 FIGURE ELECTRICAL-COMPONENTS67 FIGURE ELECTRICAL- DASHPANELASSEMBLY

68 FIGURE ELECTRICAL- LAMPSANDACCESSORIES

69 FIGURE ELECTRICAL- BEACONASSEMBLY

72 FIGURE ELECTRICAL- ENGINEMONITORINGSYSTEM

74 FIGURE SEATS,SEATBELTSANDACCESSORIES75 FIGURE HITCHES

76 FIGURE LATCHESANDFASTENERS

77 FIGURE DECALSANDDATAPLATES

78 FIGURE DECALS- CUSTOMERSPECIFIC

79 FIGURE ACCESSORIES- GENERAL

80 FIGURE ACCESSORIES- CUSTOM

81 FIGURE CAB- ASSEMBLY

82 FIGURE CAB- ACCESSORIES83 FIGURE CAB- DOORLATCHASSEMBLY

Item not illustrated4-4 FEBRUARY1996FIGURE 1APAGE 4

Page 127: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 128: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 129: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 130: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 131: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 132: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 133: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 134: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 135: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIoGERTRACTOR TIG-30.THROUGH 70C R ORATION

FIGURE 4A

REAR SUSPENSION

DATE: 9/1/96

4-4SEPTEMBER1997 FIGURE4A

PAGE 1

Page 136: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIG-30THROUGH70CORPORATI ON

4-4 REARSUSPENSION SEPTEMBER1997PAGE2 FIGURE4A

Page 137: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i'._,.. TOW TRAOTO R

TIGER T]:_(_TOR TIG-40, 50, 60CORPORATION

FIG.- TIGER FIGURE N'UMBER -- 4A UNITS

ITEM PART REAR SUSPENSION EFF. PER

NUM NUMBER ITEMDESCRIPTION ASSY.4A- REARSUSPENSION

1 959752 BRACKET,LEFTFRONT 12 987097 BRACKET,LEFTMIDDLE 1

3 969832 BRACKET,LEFTREAR 1

4 920195 BRACKET,RIGHTFRONT 1

8 949476 BRACKET,RIGHTMIDDLE 1

9 951255 BRACKET,RIGHTREAR 1

10 977832 BOLT 4

932059 LOCKNUT 4

11 924444 BUSHING,LEAFSPRING 2

12 943203 LEAFSPRING 2

13 980032 U-BOLT 3

941521 LOCKNUT 6

14 969275 BOLT,FRONT&REARBRACKETS 14

998762 BOLT,RIGHTFRONTBRACKET 2

970959 LOCKNUT 16

15 957661 U-BOLT 1

972825 LOCKNUT 2

*- Itemnotillustrated 4-4FEBRUARY1996 FIGURE4A

PAGE 3

Page 138: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 139: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

:_l__l_lS,_,q::,T@_ T,_-_0T_O_ _0

FIGURE 4B2

REAR SUSPENSION

DATE 10/1/00

4-4OCTOBER2000 FIGURE4B2

PAGE 1

Page 140: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_lg,_lS_l_,C_,To0_T,_-_oT_F_O_70

\- ..1_

I\

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Page 141: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 158: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

8F - STEER AXLE (CONT.) 34 CUP, AXLE OUTER BEARING 2 35 CONE, AXLE OUTER BEARING 2 36 WASHER, HUB OUTER BEARING 2 37 NUT, HUB BEARING KNUCKLE 4 38 WASHER 2 39 DUST CAP 2 40 BOLT 10

FIG.-ITEMNUM.

TIGERPART

NUMBER

EFF.UNITSPER

ASSY.

FIGURE NUMBER -- 8FSTEER AXLE

ITEM DESCRIPTION

JANUARY 20004-4FIGURE 8FPAGE 4

222224286461265122299456292474216139233841

Page 159: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

'I_GER T.[:_A_.CTO_ TIG-30 THROUGH 70CORPORATION

FIGURE 8G

STEER AXLE

DATE: 2/1/00

4-4FEBRUARY2000 FIGURE8G

PAGE 1

Page 160: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIG-30 THROUGH 70CORPORATION

STEERINGAXLEASSEMBLY COMPLETE

J,J

4-4 STEERINGAXLE FEBRUARY2000PAGE2 FIGURE8G

Page 161: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIoGEpRTRACTOR TIG-30 THROUGH 70CD F_ATI O N

FIG.- TIGER FIGURE NUMBER -- 86 ..... UNITS

ITEM PART STEER AXLE IEFF. PER

NUM. NUMBER ITEM DESCRIPTION ASSY.

8G - STEER AXLE

1 937544 AXLEASSEMBLY 1

2 927962 KING PIN SET WITH BRASS BUSHING A/R

927962N KING PIN SET WITH NYLON BUSHING A/R

3 932618 RODASSEMBLY 1

4 902616 TIERODEND- LH 1

5 984031 ROD 1

6 949510 CLAMPASSEMBLY 2

7 953076 TIERODEND- RH 1

8 953457 FITTING,TIERODEND 2

9 962577 COTTERPIN 2

10 965570 ARM,RIGHTHANDSTEERING 1

11 944160 KEY,STEERINGARM 2

12 983495 ARM,LEFTHANDSTEERING 1

13K 902972 SEAL 2

902977 GREASERETAINER 2

902993 CLIP, GREASE RETAINER 2

14K 983726 PIN,STEERAXLEKNUCKLE 2

15K 903426 BRASSBUSHING,KNUCKLEPIN 4

903426N NYLONBUSHING,KNUCKLEPIN 4

16 992137 BALLSTUD 1

17 949031 NUT,BALLSTUD 1

918827 COTTERPIN 1

18 942495 KNUCKLE- LH 1

19 999068 NUT,STEERINGARM 2

976778 COTTERPIN 2

20 913870 STEERINGAXLE 1

21K 973840 SHIM, STEERING AXLE KNUCKLE A/R

22K 996851 DRAWKEY 2

23K 937089 BEARING,AXLEKNUCKLE 2

24 954549 LOCKNUT,BRAKEASSEMBLY 8

25 955300 FITTING,AXLEKNUCKLE 4

26 964565 BOLT, AXLE KNUCKLE 2

27 925760 KNUCKLE- RH 1

28 959324 SEAL,STEERAXLEHUB 2

29 947214 CONE,AXLEHUBINNERBEARING 2

30 972006 CUP,AXLEHUBINNERBEARING 2

31 989298 ROTOR 2

32 996259 HUB 10

33 918696 CUP,AXLEOUTERBEARING 2

- Itemnotillustrated 4-4FEBRUARY2000 FIGURE8G

PAGE 3

Page 162: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

'-_C.TER '_']_/_C'_'O_ 716-30 THROUGH 70CORPORATION

FIG.- TIGER FIGURENUMBER--8G UNITS

ITEM PART STEERAXLE EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.

8G - STEER AXLE (CONT.)

34 995104 CONE,AXLEOUTERBEARING 2

35 964890 WASHER, HUB OUTER BEARING 2

36 992189 NUT,HUBBEARINGKNUCKLE 4

37 937878 DUSTCAP 2

38 956290 CALIPER 1

39 952126 FITTING 2

41 963840 BRAKELINE 2

42 930661 CALIPERBRACKET 2

43 997280 BOLT 4

905160 WASHER 4

44 979632 ' BOLT 4

974688 WASHER 4

45 935703 BOLT 12

928871 LOCKWASHER 12

46 945257 STUD-WHEEL 10

47 907789 GASKET 2

48 991894 PISTON- CALIPER(NOTSHOWN) 4

49 974537 BRAKE PAD - CALIPER (NOT SHOWN) 4

50 995391 RETAINER - CALIPER (NOT SHOWN) 4

51 988518 WASHER 2

* - Item not illustrated4-4 FEBRUARY2000FIGURE 8GPAGE 4

Page 163: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

:_l_l_i_qS,T@_ _,_-3oT_O_ _o

FIGURE 9C

DRAG LINKFOR MANUAL STEERING

DATE 2/1/01

4-4FEBRUARY2001 FIGURE9C

PAGE 1

Page 164: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 165: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 166: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 167: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 168: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 169: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 170: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 171: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH70CORPORATION

.FIGURE 10B1

STEER GEAR ASSEMBLY

DATE: 5/1/00

4-4MAY2000 FIGURE10B1

PAGE 1

Page 172: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TP_A_CTOR TIG-30 THROUGH 70CORPORATION

J" POWERSTEERING POWERSTEERING

, GEARANDSHAFT GEAR

_3_ _ [ ASSY. COMPLETEj............ ASSY. COMPLETEI "!_

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4-4 STEERGEARASSEMBLY MAY2000PAGE2 FIGURE10B1

Page 173: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 174: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 175: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

"_C_.,-ERT_A_CTOR Tie-g0 THROUGH 70CORPORATION

FIGURE 10E

STEER GEAR

DATE: 3/1/01

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PAGE 1

Page 176: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIG-3OTHROUGH70CORPORATION

4-4 STEERGEAR MARCH2001PAGE2 FIGURE10E

Page 177: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 178: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 179: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TP__.CTOR TIG-3OTHROUGH 70CORPORATION

FIGURE 12B

STEERING COLUMN MOUNTFOR POWER STEERING

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PAGE 1

Page 180: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIC-30THROUGH70CORPORATION

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Page 181: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 182: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 183: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

(T:::;I_,I_oT_,_(_IT_r,_ TIG-30 THROUGH 70

FIGURE 12A

STEERING COLUMN MOUNT

FOR MANUAL STEERING

DATE 12/1/97

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PAGE 1

Page 184: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 185: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 186: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 187: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_,_h_6__,.*'_-_T_^_._ o T._-_OT_O_ 70

FIGURE 13B

FRONT WHEEL AND TIRE

DATE 6/1/96

4-4JUNE1996 FIGURE13B

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Page 188: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 189: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 190: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 191: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

;_l_l_l_,q:_ T,_-30T_O_ 70

FIGURE 14H

REAR WHEEL AND TIRE

DATE 3/1/00

4-4MAROH2000 FIGURE14H

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Page 192: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 193: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 194: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 195: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

;_l__,l_,_l_,q:,T@_ T,_-3oT_o_ _o

FIGURE 15A

ENGINE -- CYLINDER BLOCK &CYLINDER HEAD

DATE 3/1/96

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4-4MARCH1996 FIGURE15A

PAGE 1

Page 196: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 197: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4

FIGURE 15APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 15AENGINE - CYLINDER BLOCK AND HEAD

ITEM DESCRIPTION 15A - ENGINE - CYLINDER BLOCK AND CYLINDER HEAD 1 DOWEL 2 2 CYLINDER ASSEMBLY 1 3 BLOCK 1 4 COVER FRONT 1 5 GASKET 1 6 BOLT 6 7 PLUG AR 8 PLUG AR 9 PLUG AR 10 PLUG AR 11 PLUG AR 12 PLUG 3 13 VALVE SEAT INSERTS 6 15 CYLINDER HEAD LESS VALVES 1 WITH EXHAUST VALVE SEAT INSERTS CYLINDER HEAD COMPLETE 1 WITH EXHAUST VALVE SEAT INSERTS CYLINDER HEAD LESS VALVES 1 16 GASKET, CYLINDER HEAD 1 17 BOLT 4 18 GASKET SET - VALVE GRIND 1 19 GASKET SET - LOWER 1

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Page 198: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 199: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_'_6_Y_"_'_-_T°^_*_o T,_-30T_OU__0

FIGURE 17A

ENGINE-- PISTON &CONNECTING RODS

DATE: 12/1/97

4-4DECEMBER1997 FIGURE17A

PAGE 1

Page 200: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 201: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70CORPORATION-FIG.- TIGER FIGURE NUMBER 17A UNITS

ITEM PART ENGINE- PISTONSAND CONNECTING EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.17A- ENGINE--PISTONSANDCONNECTINGRODS

1 256094 PISTONANDPINSTANDARD 6

265185 PISTONANDPIN- .0030/S AR

283680 PISTONANDPIN- .0200/S AR210212 PISTONANDPIN- .0300/S AR

263201 PISTONANDPIN- .0400/S 22 200286 PIN 6

3 262898 RINGSET-STANDARD 3

279009 RINGSET- .0200/S AR

209259 RINGSET- .030O/S AR276223 RINGSET-.040O/S AR

4 248016 RODASSEMBLY-CONNECTING 6

5 265630 NUTCONNECTINGROD 126 279548 BOLT 12

7 259494 BEARINGSTD. 12

239103 BEARING.001O/S

287983 BEARING.002O/S

207294 BEARING.010O/S280838 BEARING.020O/S

230082 BEARING.030O/S "

* - Itemnotillustrated 4-4FEBRUARY1996 FIGURE17A

PAGE 3

Page 202: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 203: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_l_l_:l_q:,T@_ T,_-30_O_ _0

FIGURE 18A

ENGINE -- CAMSHAFT & BEARINGS "

DATE 12/1/97

4-4DECEMBER1997 FIGURE18A

PAGE 1

Page 204: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 205: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70CORPORATION_FIG.- TIGER FIGURE NUMBER 18A UNITSITEM PART ENGINE-- CAMSHAFTAND BEARINGS EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.18A- ENGINE--CAMSHAFTANDBEARINGS

1 289908 CAMSHAFTASSEMBLY- LESSGEAR 1

2 237068 GEAR-CAMSHAFT-STEELTOOTH 13 239868 SPACER- CAMGEAR 1

4 235899 PLUG AR

5 219595 PLATE-CAMTRUST 1

6 290623 BOLT- BRACKETTOBLOCK 2

7 263974 KEY- GEARTOCAMSHAFT 1

8 277527 CAMSHAFTBEARINGSTD. 2

287459 CAMSHAFTBEARING.015U/S 2

* - Itemnotillustrated 4-4FEBRUARY1996 FIGURE18A

PAGE 3

Page 206: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 207: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 208: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 209: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-40, 50, 60

FEBRUARY 19964-4

FIGURE 19APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 19AENGINE -- CRANKSHAFT AND ASSY.

ITEM DESCRIPTION 19A - ENGINE -- CRANKSHAFT AND ACCESSORIES 1 CRANKSHAFT 1 2 GEAR - CRANK -STEEL 1 3 KEY - GEAR TO CRANKSHAFT 1 4 BOLT 14 5 PULLEY - INNER 1 6 BOLT 1 7 WASHER 1 8 PULLEY ASSEMBLY - OUTER 1 9 BOLT 3 10 MAIN BRG. - LOWER STANDARD 6 MAIN BRG. - LOWER .001 U/S AR MAIN BRG. - LOWER .002 U/S AR MAIN BRG. - LOWER .010 U/S AR MAIN BRG. - LOWER .020 U/S AR MAIN BRG. - LOWER .030 U/S AR MAIN BRG. - UPPER STANDARD 6 MAIN BRG. - UPPER .001 U/S AR MAIN BRG. - UPPER .002 U/S AR MAIN BRG. - UPPER .010 U/S AR MAIN BRG. - UPPER .020 U/S AR MAIN BRG. - UPPER .030 U/S AR 11 THRUST BRG. - UPPER STD 1 THRUST BRG. - UPPER .001 U/S AR THRUSR BRG. - UPPER .002 U/S AR THRUST BRG. - UPPER .010 U/S AR THRUST BRG. - UPPER .020 U/S AR THRUST BRG. - UPPER .030 U/S AR THRUST BRG. - LOWER STD 1 THRUST BRG. - LOWER .001 U/S AR THRUST BRG. - LOWER .002 U/S AR THRUST BRG. - LOWER .010 U/S AR THRUST BRG. - LOWER .020 U/S AR THRUST BRG. - LOWER .030 U/S AR 12 OIL SEAL - FRONT COVER 1 13 OIL SEAL - CRANKSHAFT REAR 1

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Page 210: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 211: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 212: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 213: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-40, 50, 60

FEBRUARY 19964-4

FIGURE 20APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 20AENGINE -- VALVE TRAIN

ITEM DESCRIPTION 20A - ENGINE -- VALVE TRAIN 1 TAPPET 12 2 VALVE - EXHAUST 6 VALVE - INTAKE 6 3 VALVE SPRING - INTAKE 6 VALVE SPRING - EXHAUST 6 4 RETAINER - INTAKE 6 RETAINER - EXHAUST 6 5 LOCK KEY 24 6 COVER - PUSH ROD 1 7 BOLT AND GROMMET ASSY. 6 8 GASKET - PUSH ROD COVER 1 9 GUIDE - ROCKER ARM FULCRUM 12 10 SEAT - ROCKER AND FULCRUM 12 11 BOLT - ROCKER ARM SUPPORT 12 12 ARM - VALVE ROCKER 12 13 ROD - VALVE PUSH 12 14 SEAL - VALVE STEM 12 15 COVER - ROCKER ARM 1 16 BOLT 8 17 GASKET - ROCKER ARM COVER 1 18 RETAINER 2 19 OIL FILLER CAP 1 20 FILTER ASSY - CRANKCASE VENT TUBE 1 21 PCV VALVE AND ELBOW CONNECTOR 1

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Page 214: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 215: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 216: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 217: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-40, 50, 60

FEBRUARY 19964-4

FIGURE 24APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 24AENGINE -- OIL PUMP AND OIL PAN

ITEM DESCRIPTION 24A - ENGINE -- OIL PUMP AND OIL PAN 1 PUMP ASSEMBLY NOT INCLUDING SCREEN AND TUBE 1 2 BOLT 2 3 SHAFT ASSEMBLY 1 4 SCREEN, TUBE AND COVER 1 5 GASKET, OIL PUMP - ONE PIECE 1 6 BOLT 2 7 INDICATOR - OIL LEVEL 1 8 TUBE, OIL LEVEL INDICATOR 1 9 GASKET - OIL PAN - ONE PIECE 1 10 PAN - ENGINE OIL 1 11 PLUG - OIL DRAIN 1 GASKET - OIL DRAIN PLUG AR 12 BOLT - REINFORCEMENT RAILS 25 13 BOLT - NO REIFORCEMENT RAIL 25 14 REINFORCEMENT RAIL, R AND L 1

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Page 218: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 219: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 220: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4FIGURE 25APage 2

ENGINE -- OIL FILTER ASSEMBLYFIGURE 25A

Page 221: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70CORPORATIONFIG.- TIGER FIGURE NUMBER -- 25A UNITS

ITEM PART ENGINE-- OIL FILTERASSEMBLY EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.25A- ENGINE-- 01LFILTERASSEMBLY1 287924 01LFILTER 1

2 282962 GASKET 1

3 251252 ADAPTER 1

4 262580 GASKET 1

5 272600 BOLT-ADAPTERMOUNTING 1

6 212121 INSERT-OILFILTERADAPTER 1

*- Itemnotillustrated 4-4FEBRUARY1996 FIGURE25A

PAGE 3

Page 222: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 223: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 224: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 225: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 226: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 227: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 228: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

DECEMBER 19974-4FIGURE 27APAGE 2

ENGINE -- MANIFOLDSFIGURE 27A

1

2

87

3

5

6

12

910

13

414

Page 229: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 230: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 231: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � �� � � � � � � � � � �

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Page 232: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

JUNE 19994-4FIGURE 28APAGE 2

ENGINE-EXHAUST SYSTEMFIGURE 28A

5

62

4

6

5

78

6

6

5

Page 233: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 234: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 235: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 236: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

JANUARY 19974-4FIGURE 29CPAGE 2

ENGINE-CARBURETOR AND GOVERNORFIGURE 29C

REBUILDKIT

ASSEMBLYCOMPLETE

1

3

4

5

4

6

4

7

2

Page 237: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 238: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 239: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � �� � � � � � � � � � �

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Page 240: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19974-4FIGURE 30APAGE 2

FUEL SYSTEM ASSEMBLYFIGURE 30A

12

13

5

14

1

3

4

7

86

5

10

211

Page 241: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-40, 50, 60

SEPTEMBER 19974-4

FIGURE 30APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 30AENGINE -- FUEL SYSTEM

ITEM DESCRIPTION 30A- ENGINE -- FUEL SYSTEM 1 FUEL PICK - UP TUBE 1 2 CLAMP - FUEL HOSE 4 3 FUEL LINE 1 4 HOSE - FUEL 2 5 FUEL PUMP 1 6 GASKET 1 7 FUEL LINE 1 8 BOLT 2 LOCKWASHER 2 10 FUEL DEFLECTOR TUBE 1 11 ADAPTOR - FUEL LINE TO HOSE 1 12 FUEL FILTER COVER 1 13 FUEL FILTER 1 14 O - RING 1

228963222062288890201402211890221528284336276122207143262039292527250194298595249479

Page 242: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 243: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

(:_l(_l_'O:)_=_,_l_ nTI("2_I: DTDA P'T_ND TIG-30 THROUGH 70

FIGURE 33N

ENGINE -- AIR CLEANER

DATE- 8/1/02

4-4AUGUST2002 FIGURE33N

PAGE 1

Page 244: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

_lg_._oT,_AC,To_ T,_-_0_-_o_ _0

t

AIRCLEANERASSEMBLY COMPLETE

4-4 AIRCLEANER AUGUST2002PAGE2 FIGURE33N

Page 245: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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� � ' � � � � � � ! $ ( & ) * � � � � � � & ! � " ! � � + � " � & � % ! � � , � � � � - � � �'

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� � � � � � & � $ # � � � �

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� � � � � � � # � � � '

� 1 � � � � � � ! � � � '

� 2 � � � ( � ! � � � ! � � � % � # � � � � � � '

� ' � � � � ( � & � � � � '

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. � � . � .

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Page 246: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 247: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_'_6_'_"T'_-_T°^r*_T,_-30T_OU__0

FIGURE 34B

ENGINE-- EMISSION CONTROLS

DATE: 6/1/00

JUNE2000 4-4FIGURE 34B

PAGE 1

Page 248: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

T,G-3OTHROUGH70

4-4FIGURE 34B ENGINE-EMISSION CONTROLS JUNE 2000PAGE2 FIGURE34B

Page 249: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

FIG.- TIGER FIGURENUMBER-- 34B UNITS

ITEM PART ENGINE-- EMISSIONCONTROLS EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.34B- ENGINE--EMISSIONCONTROLS

1 281256 HOSE 1

2 222880 ELBOW 1

3 225708 HOSE 14 253302 HOSE 1

5 283751 CLAMP 2

6 289774 HOSE 1

7 223380 HOSE 1

8 260797 CAP 1

9 266887 HOSE 1

10 265226 TEE 111 230650 PCVVALVE 1

*- Itemnotillustrated 4-4AUGUST2002 FIGURE34B

PAGE 3

Page 250: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 251: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 252: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

MARCH 19964-4FIGURE 35APAGE 2

ENGINE IGNITION SYSTEMFIGURE 35A

12

13 14

15

16

17

1

2

35

4

6

7

8

9

10

11

18

19

Page 253: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

JUNE 19994-4

FIGURE 35BPAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 35BENGINE -- IGNITION SYSTEM

ITEM DESCRIPTION 35B- ENGINE -- IGNITION SYSTEM 1 COIL ASSEMBLY 1 2 STRAP 1 3 BOLT 1 4 NUT 1 5 STUD AR 6 WIRE ASSEMBLY - COIL TO DISTRIBUTOR 1 7 ENGINE WIRE HARNESS 1 8 WIRE SET-SPARK PLUG- 1 9 SPARK PLUG 6 10 MODULE 1 11 ROTOR 1 12 RELUCTOR 1 13 PLATE ASSEMBLY 1 14 SET SCREW 1 15 DISTRIBUTOR BODY 1 16 SHAFT ASSEMBLY 1 17 MAGNETIC PICK-UP 1 18 CAP 1 19 SPACER 1

299655287850231705262670206922261169250143253829275758238757257209264455204423295442242299274566212417268315212761

Page 254: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 255: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 256: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4FIGURE 36APAGE 2

ENGINE-ALTERNATOR MOUNTINGFIGURE 36A

1

2

3

4

5

6

78

Page 257: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 258: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 259: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 260: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4FIGURE 37APage 2

CHARGING SYSTEMFIGURE 37A

Page 261: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

UUNE 19994-4

FIGURE 37APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 37AENGINE - ALTERNATOR & VOLTAGE

ITEM DESCRIPTION 37A - ENGINE -- ALTERNATOR AND VOLTAGE REGULATORD 1 ASSEMBLY COMPLETE 1 2 SCREW 1 LOCKWASHER 1 3 NUT 1 LOCKWASHER 1 4 COLLAR 1 5 FRAME 1 6 BEARING 1 7 PLATE 1 8 SCREW 3 9 COLLAR 1 10 ROTOR ASSEMBLY 1 11 STATOR 1 12 TERMINAL PACKAGE 1 13 SCREW 1 LOCKWASHER 1 14 BEARING 1 15 FRAME 1 16 BRUSH HOLDER, ALTERNATOR 1 17 BRUSH HOLDER & BRUSH ASSEMBLY 1 18 BRUSH SPRING 2 19 CAPACITOR 1 20 BRACKET 1 21 SCREW 1 22 SCREW 1 23 SCREW 2 24 SEAL 1 25 OIL SLINGER 1 26 THROUGH BOLT 4 27 TERMINAL 3 28 VOLTAGE REGULATOR 1 29 RECTIFIER ASSEMBLY 1 30 DIODE TRIO 1 31 NUT 3 LOCKWASHER 3 32 FAN 1 33 PULLEY 1

221400223864205868209242253397270047262362287918249865289636211881281288200373271982255117298754229875234010258221295135253163213457240596288075215983267291268758257377271091286341217738282666280413211336226028205228241830

Page 262: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 263: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 264: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGE

R TR

AC

TOR

CO

RPO

RATIO

N

TOW

TRA

CTO

RTIG

-30 THR

OU

GH

70

JUN

E 1999

4-4FIG

UE

R 38A

PA

GE

2E

NG

INE

-STA

RTE

RFIG

UR

E 38A

Page 265: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

38A ENGINE -- STARTER & ASSEMBLY 1 STARTER COMPLETE 1 2 ARMATURE 1 3 WASHER 1 4 PLATE & BEARING 1 5 HOLDER - INCLUDES BRUSHES 1 6 LEVER 1 7 FRAME & MAGNET ASSEMBLY 1 8 BOLT 2 9 ATTACHING KIT A/R CONSISTS OF; 1 10 NUT & WASHER 1 11 SCREW 2 13 HOUSING 1 14 BEARING 1 15 BEARING 3 16 BEARING 1 17 GEAR 1 18 RETAINER 1 19 SEAL 1 20 BALL 1 21 GEAR ASSEMBLY 3 22 RING 1 23 RETAINER 1 24 DRIVE ASSEMBLY 1 25 SHAFT ASSEMBLY 1 26 SOLENOID 1 27 RING 1 28 COVER 1

SEPTEMBER 19974-4

FIGURE 38APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 38AENGINE --STARTER

ITEM DESCRIPTION

22119628765928644027326024319320037722585

297808248093261182213285260587242676215161286489245144205570212745220546227754292599237466293691207201252560253306232612269754

Page 266: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 267: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_l_i_oTl__ _,_-_oT_O_ _0

FIGURE 45E

FUEL CELL & ACCESSORIES

DATE: 8/1/02

4-4AUGUST2002 FIGURE45E

PAGE 1

Page 268: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

_iS_f_,_,?,To0_T,_-_0-r_OU__0

4-4 FUEL CELL AND ACCESSORIES AUGUST 2002PAGE45E FIGURE45E

Page 269: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 270: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 271: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 272: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGE

R TRAC

TOR

CO

RPO

RATIO

N

TOW

TRA

CTO

RTIG

-30 THR

OU

GH

70

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RU

AR

Y 1996

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2

3

4

5

6

7

8

9 10

11

12

13

14

1

Page 273: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

l oTl q:,ToOTIG.- TIGER FIGURE NUMBER -- 46A UNITSITEM PART ACCELERATOR LINKAGE EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY,46A- ACCELERATORLINKAGE

1 275858 BOLT 2

292812 LOCKWASHER 22 283788 PEDAL 1

3 251023 ARM 1

4 263246 NUT 1

229663 WASHER 1

5 292146 BALLSTUD 1

6 219413 THROTTLECABLE 1

7 272533 BOLT 1

8 233774 CLIP 19 292648 SPRING 1

10 267147 BOLT 2

221614 WASHER 2

11 240210 BRACKET 112 293503 SPACER 4

13 266789 BOLT 2

212248 LOCKWASHER 2

14 292388 BRACKET 1

* - Itemnotillustrated 4-4FEBRUARY1996 FIGURE46A

PAGE 3

Page 274: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 275: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 276: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

DECEMBER 19974-4PAGE 2

TORQUE CONVERTER AND FLYWHEELFIGURE 47A

2

6

45

3

1

Page 277: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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� � � � � � � � ( � ) � � / ) � � � ( � � � ) 0 � � � !

� 1 � � � � , � � � � , � � ( ( � & � , � / ) � � � ( � � � ) 0 � � �!

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� ! - � � � � � % ( � � � � 2 � � , � � � � , � � � � ( � ) � � / ) � � � ( � � � ) 0 � �#

� ! � � � � , � � 3 � � ( � � � 2 � � � � ( � ) � � � � ( � � ) � � � / ) � � � ( � � � ) 0 � �#

� ! $ � � � ' � � � , 2 � � , � � � � , � � � � ( � ) � � / ) � � � ( � � � ) 0 � ��!

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- # 1 1 ! $

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- $ $ $ 1 �

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Page 278: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 279: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70C;O F_PO m_,TI C) N

FIGURE 48B

TRANSMISSION -- ASSEMBLY

DATE: 1/1/01

4-4JANUARY2001 FIGURE48B

PAGE 1

Page 280: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRAOTOR

_1_ _oT#_(_,To0_R T,G-30THROUGH70

FRONT PUMP INTERMEOIATE DRUM

B_ '

DIRECT CLUTCH FORWARD CLUTCH L INPUTSHEL IrSUN GEAR

c,4_1 REVERSE CLUTCH OVERRUN CLUTCH

96-126

PAN

4-4 TRANSMISSION LINKAGE JANUARY 2001PAGE2 FIGURE48B

Page 281: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

vv____..--.__I__I_(_N R TIC-30 THROUGH 70

FIG.- TIGER FIGURENUMBER-- 48B UNITS

ITEM PART TRANSMISSIONASSEMBLY EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.48B- TRANSMISSIONASSEMBLY

1 285893 FRONTPUMPSEAL,W/FLANGE 1268425 FRONTPUMPSEAL,W/OFLANGE 1

2 274036 FRONTPUMPBODY- BRONZE- W/WHITEFLASH 1263725 FRONTPUMPBODY- BABBITI 1

3 289861 SEAL- LATHECUT- FRONTPUMPHOUSING 1

4 253143 FRONTPUMPASSEMBLY- COMPLETE 1

5 220463 FRONTGEARSET 1

6 273822 STATORSUPPORTPUMPCOVER- FRONT 17 202011 STATOR 1

8 290250 STATORSUPPORTPUMPCOVER- REAR 1

9 255631 FRONTPUMPSELECTIVES- METAL- .057 AR

230974 FRONTPUMPSELECTIVES- METAL- .074 AR

209509 FRONTPUMPSELECTIVES- METAL- .089 AR

218680 FRONTPUMPSELECTIVES- METAL- .104 AR217735 FRONTPUMPSELECTIVES- METAL- .119 :".. AR

213968 FRONTPUMPSELECTIVES- PLASTIC- .057 I: AR258924 FRONTPUMPSELECTIVES- PLASTIC- .074 AR

221712 FRONTPUMPSELECTIVES- PLASTIC- .089 AR268599 FRONTPUMPSELECTIVES- PLASTIC- .104 AR

232890 FRONTPUMPSELECTIVES- PLASTIC- .119 AR

10 234582 INTERMEDIATEBRAKEDRUM- STATOR _. 2,,!

11 246478 GASKET-FRONTPUMPTOCASE 1 .12 272458 INTERMEDIATEBANDS 1

13 215011 INTERMEDIATEBRAKEDRUM- FRONT3/8"WIDE 114 249945 INTERMEDIATEBRAKEDRUMASSY- 3PLATE 1

297693 INTERMEDIATEBRAKEDRUMASSY- 4 PLATEO 1

15 233900 INTERMEDIATEBRAKEDRUM- REAR- 1 1/4"WIDE 116 210850 INTERMEDIATEBRAKEDRUM-4TABS 1

17 292301 FRICTION- DIRECT- 63TEETH 3/418 253971 STEEL- DIRECT- .015OVERSIZE AR

277939 STEEL- DIRECT-KOLENE AR

244639 STEEL- DIRECT- FLAT 3/419 267599 DIRECT-FLAT 1

20 291035 FORWARDCLUTCHCYLINDER 2

21 234125 FORWARDCLUTCHCYLINDER 1

22 241276 PISTON-FORWARD 1

23 295290 SEAL- LATHECUT- FORWARDCLUTCHPISTION 1215593 SEAL- LIP- FORWARDCLUTCHPISTON- OUTER 1

24 282640 FORWARDCLUTCHDIAPHRAGM: 5/64"THICK 1

Item not illustrated 4-4JANUARY2001 FIGURE48B

PAGE 3

Page 282: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

v_______...__I_,_I_I_Q',-F.D.R TIG-30 THROUGH 70

FIG.- TIGER FIGURENUMBER 488 UNITS

ITEM PART TRANSMISSION ASSEMBLY EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.48B- TRANSMISSIONASSEMBLY

24 207125 FORWARDCLUTCHDIAPHRAGM3/32"THICK 1

25 247741 FORWARD&DIRECTCLUTCH-SELECTIVE- .076 AR

290815 FORWARD&DIRECTCLUTCH- SELECTIVE- .OB5 AR

291798 FORWARD& DIRECTCLUTCH- SELECTIVE- .094 AR

26 267768 FORWARD-FRONT-BEVEL 1 .,

27 221615 FRICTION- FORWARD- 90TEETH- .063THICK 3/5257468 FRICTION- FORWARD- 90TEETH- .077THICK 4

268126 FRICTION- FORWARD- SPECIALLYHARDTEETH 4

28 207052 STEEL- FORWARD- .015OVERSIZE AR

222411 STEEL- FORWARD- FLAT 3/4283124 STEEL- FORWARD- WAVED 3/4

277814 STEEL- FORWARD- FLAT- KOLENE 429 272974 FORWARD-REAR-FLAT 1

30 252281 BEARING- RACE- FRONT 1/2

31 260169 BEARING- W/42ROLLERS 1/232 229206 BEARING& RACEPACKAGE 1/2

274710 BEARING& RACEASSEMBLY 1/233 281868 FORWARDCLUTCHHUB-3TABS 1

34 286245 FORWARDRINGGEARHUB 1

35 291885" FORWARDRINGGEAR-NARROW 1

244238 FORWARDRINGGEAR&HUB 1

36 246651 FORWARD& REVERSEPLANETCARRIER- 6 TABS 2/337 272743 FRONTPLANETARYASSEMBLY 1

38 268544 SUNGEARBUSHING- HARDERBRONZE 2

39 272173 SHELLW/SUNGEAR 1

40 270101 REARPLANET-C6 1

41 213177 REVERSEPLANETCARRIER-4TABS 142 228386 OUTPUTSHAFTHUB- 3TABWASHERTYPE 1

43 225524 OUTPUTSHAFTHUB-2TANGS 1

283111 OUTPUTSHAFTHUB- 3TANGS 1

224336 OVERRUNRACE/OUTPUTSHAFTHUB- 3 PIECE 1

44 220021 FRICTION- REVERSE- 72TEETH 4/6

45 240369 STEEL- REVERSE- 18 TEETH 4/5

262512 STEEL- REVERSE- 18TEETH- KOLENE 4/5

214253 STEEL- REVERSE- 18 TEETH- .082" 4/5

46 208971 CLUTCHSPRING& ROLLERKITW/WASHERBRG. 1

233804 CLUTCHSPRING& ROLLERKITW/OWASHERBRG. 147 242936 OVERRUNCLUTCHINNERRACE- 1.090WIDE 1

277594 OVERRUNCLUTCHINNERRACE- 1.013WIDE3 PC. 1

Itemnotillustrated 4-4JANUARY2OO1 FIGURE48B

PAGE 4

Page 283: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_v__._..__.__I__0,T_N R TIC-30 THROUGH 70q-i£J.- TIGER FIGURENUMBER 48B UNITS

ITEM PART TRANSMISSIONASSEMBLY EFF PER

NUM NUMBER ITEMDESCRIPTION ASSY48B- IRANSMISSIONASSEMBLY

48 256584 GASKET,INTERMEDIATESERVOPISTONCOVER 1

49 275790 PISTON- W/COVER- SUPERSERVO 1252853 INTERMEDIATESERVOPISTONS- 2.095- CA 1

223296 INTERMEDIATESERVOPISTONS- 1.980- BA 1

213689 INTERMEDIATESERVOPISTONS- 2.130- DA 1

219903 INTERMEDIATESERVOPISTONS- 2.050- AA 1

50 201449 GASKET- EXTENSIONHOUSINGTOCASE 1

51 255190 CASEBUSHING- REAR 1267149 CASEBUSHING- OVERSIZE 1

52 276832 GOVERNORHOUSING 3

53 268329 GOVERNORBODY 1

54 229165 EXTENSIONHSGSEAL- W/OBOOT,W/FLANGE 1263143 EXTENSIONHSGSEAL- W/BOOT 1

220786 EXTENSIONHSGSEAL- W/OBOOT- 3.066O.D. 155 210916 EXTENSIONHOUSING 1

56 277922 VALVEBODY 1

57 238958 GASKET,OILSCREEN 1

58 241452 FILTER,SCREEN 1

59 228394 VACUUMMODULATOR-WHITESTRIPE- SCREWIN ,! 1215891 VACUUMMODULATOR-BROWNSTRIPE- PUSHIN 1

246565 VACUUMMODULATOR- PURPLESTRIPE- PUSHIN _. 1

235908 VACUUMMODULATOR- GREENSTRIPE- PUSHIN ,_ 1

60 281687 O-RING- MODULATOR-PUSH-INMODULATOR 161 228979 OUTPUTSHAFTREAR 1

62 281165 CASEBUSHING- FRONT- W/3OILGROOVES 163 269201 CONTROLLEVERSEAL 1

64 226769 INTERMEDIATEBANDADJ.NUTW/SEAL 165 217613 GASKET- OILPAN- CORK&NEOPRENE 1

283481 GASKET-OILPAN-FIBRE 1

281803 GASKET-OILPAN- KORCORK 166 260339 GROMMET- SHIFTLEVER- LARGE 1

286513 GROMMET- SHIFTLEVER- SMALL 1

* 288590 QUADRING- THROTTLESHAFT 1

* 271451 O-RING- FILLERTUBE 1

* 200611 CASEFITTING- 3/16"X1/4" 1

* 293736 FILTERKIT- ALL 1

* 247487 BUSHINGKIT- COMPLETE 1

* 272936 SEALINGRINGKIT- COMPLETE 1

* 240394 WASHERKIT- FRONTPUMPSELECTIVES- METAL 1

- Item not illustrated 4-4JANUARY2001 FIGURE48B

PAGE 5

Page 284: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

-_v-----.----_I_I_I_0'T_N R TIG-30 THROUGH 70I-lid.- TIGER - FIGURE NUMBER -- 48B - UNITS

ITEM PART TRANSMISSION ASSEMBLY EFF. PER

NUM. NUMBER ITEM DESCRIPTION ASSY.4BB- IHAN_MI:5:51UNA_i:51-MI:ILY

* 289283 WASHERKIT- W/OSELECTIVES 1

* 288813 BEARINGKIT 1

* 220157 SNAPRING,OUTPUTTOPARKGEAR 1

* 274518 SNAPRING,OUTPUTTORINGGEARHUB t

* 227721 OVERRUNRACE/THRUSTBEARINGKIT 1* 296147 NUT- BANDADJUSTING 1

* 251402 BOOST- VALVE/SLEEVE- GAS 1

* 241759 BOOST- VALVE/SLEEVE- DIESEL 1

* 276242 OUTPUTSHAFTHUB- BRGTYPE- W/RINGGEAR 1* 203186 GASKET- VALVEBODY- COMPOSITE 1

* - Itemnotillustrated 4-4

JANUARY2001 FIGURE48BPAGE 6

Page 285: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

TIGER TRACTOR TIG-30 THROUGH 70CORPORATION

FIGURE 54B

TRANSMISSION -- LINKAGE

DATE 2/1/01

4-4FEBRUARY2001 FIGURE54B

PAGE 1

Page 286: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR --_

_-_C_6RR][_6_T0 R TIG-30THROUGH70

_w

,X ,

(_ TRANSMISSION ASSEMBLY lCOMPLETE

4-4 TRANSMISSIONASSEMBLY JANUARY 2001PAGE2 FIGURE54B

Page 287: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 288: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 289: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_,_6__,,*'_-_*° _*_° _,_-3oT_ou__o

FIGURE 55A

TRANSMISSION -- SHIFTER ASSEMBLY

DATE: 2/1/96

4-4FEBRUARY1996 FIGURE55A

PAGE 1

Page 290: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRAOTOR

_1_ _ _.C_,_,::_N R TIG-30 THROUGH 70

NUMBERS MARKED "N"

_ %- __@

4-4 TRANSMISSION SHIFTER ASSEMBLY FEBRUARY 1996FIGURE55A FIGURE55APAGE 2

Page 291: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 292: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 293: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_'_6_,_"T'_'_*°^_°T,_-30T_O_ 70

FIGURE 56A2

TRANSMISSION -- COOLING SYSTEM

DATE 1/1/02

4-4JANUARY2002 FIGURE56A2

PAGE 1

Page 294: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

_I_£_,_,_,_NR T,G-30THROUGH70........

NOTE: IF TRACTOR HAS SOLID LINES GOING TO THE RADIATORORDER NEW TRANSMISSION LINE AND FLEX LINE.

4-4FIGURE 56A2 TRANSMISSION COOLING LINES JANUARY 2002PAGE2 FIGURE56A2

Page 295: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 296: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 297: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

:_l_l_:l_A__ T,_-_oT._O_. 70

FIGURE 57E

PARKING BRAKE ASSEMBLY

DATE 4/1/02

4-4APRIL2002 FIGURE57E

PAGE 1

Page 298: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 299: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 300: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 301: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_'_6_Y_"_'_'_T°^_*__ T,_-_OThrOUgH_0

FIGURE 58B

DRIVESHAFT ASSEMBLY

DATE" 1/1/01

4-4JANUARY2001 FIGURE58B

PAGE 1

Page 302: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 303: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 304: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 305: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_l_l_,_l_,__ T,_-_oT_O_ _0

FIGURE 59E

DRIVE AXLE

DATE: 8/1/02

4-4AUGUST2002 FIGURE59E

PAGE 1

Page 306: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 307: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

--FIG.- TIGER FIGURE NUMBER 59E UNITS

ITEM PART DRIVE AXLE EFF. PER

NUM NUMBER ITEMDESCRIPTION ASSY.59E- DRIVEAXLE

1 265869 DRIVEAXLEASSEMBLY 12 258998 DRIVEAXLEASSY.LESSBRAKES 1

3 201094 BEARING 2

4 257283 CARRIERASSY. 1

5 270162 GEAR&PINIONSET 1

6 296253 BOLTKIT 1

7 262079 THRUSTWASHER 2

8 246617 SIDEGEAR 2

9 293551 SPIDER 110 275337 PINION 4

11 230604 PINIONTHRUSTWASHER 4

12 254702 CAPSCREW 8

13 291756 DIFFERENTIAL&AXLEHOUSINGASSY,LH 114 202354 BREATHER 1

15 256521 PLUG 1{

16 224775 DIFFERENTIAL&AXLEHOUSINGASSY,RH 1

17 232811 STUD 6:18 261633 PLUG 1

19 229935 BOLT 11"

20 232596 WASHER 11.

21 264381 NUT 1122 231394 CUP 2

23 265783 PIN 1

24 275267 THRUSTBLOCK 1

25 211353 GASKET 1

26 212665 SHAFT 127 237611 SHAFT 1

28 211445 COLLAR 2

29 289937 CUP 4

30 265198 BEARING 4

31 298749 SHIMSET 2

32 260043 RETAINER 2

33 291414 GASKET 234 267041 RETAINER-OILSEAL 2

35 245494 LOCKWASHER 12

36 212576 CAPSCREW 12

37 286736 HUB 2

38 206088 ROTOR 2

39 283972 STUD 16

Itemnotillustrated 4-4AUGUST2002 FIGURE59E

PAGE 3

Page 308: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_._____..__;rJ__i_:1__ _,_-_oSH_O_H_OFIG.- TIGER FIGURE NUMBER -- 59E UNITS

ITEM PART DRIVEAXLE EFF. PER

NUM. NUMBER ITEMDESCRIPTION ASSY.

59E- DRIVEAXLE(CONT.)43 230203 LUGNUT 16

44 207567 WASHER 2

45 290375 NUT 2

46 202289 C0]-[ERPIN 2

47 219189 GASKET 1

48 256259 L0CKRING 1

49 259647 BEARING 150 229080 BEARING 2

51 280748 CAGEASSEMBLY 1

52 248705 CUP 2

53 281167 DOWEL 1

54 228329 GASKET 1

55 261194 SPACER AR

56 278409 WASHER 190 283126 0-RING 2

- Item not illustrated4-4 AUGUST2002

FIGURE 59EPAGE 4

Page 309: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 310: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 311: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

MARCH 19964-4

FIGURE 60APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 60AREDUCTION GEARBOX

ITEM DESCRIPTION 60A - REDUCTIOIN GEARBOX 1 OIL SEAL 1 2 CASE AND COVER ASSY. 1 3 WASHER 6 4 NUT 6 5 GEAR 1 6 KEY 1 7 NUT 2 8 LOCKNUT 1 9 COTTER PIN 1 10 NUT 1 11 WASHER 1 12 FLANGE 1 13 OIL SEAL 1 14 CAP 1 15 GASKET 1 16 CAPSCREW 4 17 LOCKWASHER A/R 18 DRAIN PLUG 1 19 BEARING 1 20 SPACER 2 21 GEAR & SHAFT 1 22 BEARING (WITH SNAP RING) 1 23 SNAP RING 1 24 GASKET 1 25 SPACER 1 26 DOWEL 2 27 PLUG 1 28 GASKET 1 29 CAP 1 30 CAPSCREW 4 31 BOLT 15 32 LOCKWASHER 15 33 NUT 15

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Page 312: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 313: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_1,__I_oT_,_,__R TIG-30 THROUGH 70

FIGURE 61A

BRAKES -- REAR ASSEMBLY

DATE 2/1/96

4-4FEBRUARY1996 FIGURE61A

PAGE 1

Page 314: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIG-30 THROUGH 70COR PORATI ON

j/z \v "

ASSEMBLY

_ /-- COMPETE

4-4 BRAKES-REARASSEMBLY FERUARY1996PAGE61A FIGURE61A

Page 315: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4

FIGURE 61APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 61ABRAKES -- REAR ASSEMBLY

ITEM DESCRIPTION 61A - BRAKES -- REAR ASSEMBLY 1 CALIPER ASSEMBLY-LH 2 CALIPER ASSEMBLY-RH 2 2 PISTON SEAL KIT 4 3 PISTON 2 4 BRAKE PAD KIT 4 5 RETAINER 4 6 BUSHING 8 7 SLEEVE 8 8 VALVE 4 9 BOLT 8

288604282752202130291148219668291497295983201274292879290716

Page 316: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 317: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 318: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4FIGURE 63APAGE 2

BRAKES-LINESFIGURE 63A

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Page 319: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 320: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 321: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

_1__c_(_To0_ R T,G-a0THROUGH70

FIGURE 63E

BRAKES -- LINES

DATE" 1/1/00

4-4JANUARY2000 FIGURE63E

PAGE 1

Page 322: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTORTIGER TRACTOR TIG-30THROUGH70 ..C O RPO RATI O a

4-4 BRAKES -- LINES 'JANUARY 2000PAGE2 FIGURE63E

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Page 323: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 324: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 325: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 326: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

DECEMBER 19974-4FIGURE 64APAGE 2

BRAKE SYSTEMFIGURE 64A

1

2

3

4

5

6

7

8

5

9

10

MASTER CYLINDER&

BRAKE BOOSTERASSEMBLY

11

MASTER CYLINDERREPAIR KIT

12

Page 327: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 328: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 329: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � �� � � � � � � � � � �

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Page 330: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4FIGURE 68APAGE 2

ELECTRICAL-LAMPS AND ACCESSORIESFIGURE 68A

5

6

7

4

3

1

2

Page 331: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

* - Item not illustrated

TOW TRACTORTIG-30 THROUGH 70

FEBRUARY 19964-4

FIGURE 68APAGE 3

FIG.-ITEMNUM.

TIGERPART

NUMBEREFF.

UNITSPER

ASSY.

FIGURE NUMBER -- 68AELECTRICAL -- LAMPS & ACCESSORIES

ITEM DESCRIPTION 68A- ELECTRICAL -- LAMPS & ACCESSORIES 1 WASHER 2 LOCKWASHER 2 NUT 2 2 BOLT 2 LOCKNUT 2 3 MOUNTING BRACKET 2 4 HEAD LAMP - BULB 2 5 HEAD LAMP ASSEMBLY 2 6 BRAKE/LAMP (RED) 2 WIRING PIGTAIL 2 7 BACK-UP LAMP (CLEAR) 2 WIRING PIGTAIL 2 * MOUNTING GROMMET FOR BRAKE/TAIL AND BACK-UP LAMPS 4

243304243626212680221504257864253474225864242685290266234892235027216101

228399

Page 332: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 333: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOW TRACTOR

d:::'_::_h_6_,_,_ffllc:YnTIFL"I:"DTID^PTrhNID TIG-30 THROUGH 70

FIGURE 73A

ELECTRICAL-- SHIFT INHIBITOR

DATE: 3/1/96

4-4MARCH1996 FIGURE73A

PAGE 1

Page 334: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TOWTRACTOR

_I,_,,_,(_O0N R T,G-30THROUGH70

4-4 ELEOTRIOAL-- SHIFT MARCHFIGURE73A INHIBITOR 1996PAGE2 FIGURE73A

Page 335: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 336: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 337: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 338: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

MAY 19984-4FIGURE 74CPAGE 2

SEAT ASSEMBLYFIGURE 74C

Page 339: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 340: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 341: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 342: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

MAY 19984-4FIGURE 75A1PAGE 2

HITCH ASSEMBLYFIGURE 75A1

9

10

4

5

6

7

8

ASSEMBLY COMPLETE13 1/2 INCH HITCH

2

3

4

5

6

1

ASSEMBLY COMPLETE8 1/2 INCH HITCH

7

Page 343: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 344: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 345: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 346: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

SEPTEMBER 19974-4FIGURE 75CPAGE 2

SIDE HITCHFIGURE 75C

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Page 347: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 348: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 349: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 350: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 351: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 352: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 353: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 354: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

FERUARY19964-4FIGURE 77APAGE 2

DECALS AND DATA PLATESFIGURE 77A

Page 355: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 356: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 357: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

SEPTEMBER 19974-4

FIGURE 79BPAGE 1

FIGURE 79B

ACCESSORIES - GENERAL

DATE: 9/1/97

Page 358: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

SEPTEMBER 19974-4PAGE 79B

ACCESSORIES-GENERALFIGURE 79B

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Page 359: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 360: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 361: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 362: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

TIGER TRACTORCORPORATION

TOW TRACTORTIG-30 THROUGH 70

SEPTEMBER 19974-4FIGURE 80BPAGE 2

ACCESSORIES -- CUSTOMERSPECIFIC

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Page 363: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 364: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 365: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 370: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 372: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 373: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 374: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

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Page 376: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

� � � � � � � � � � � � � � � � � � �� � � � � � � � �

Page 377: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

CSG649

INDUSTRIAL ENGINE,.' , SERVICE MANUAL

1/

PPO-194 210-8(

Page 378: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

..., ,,intrrndHntinn.________._.. ............ " ,.- " '..-_.:i.._._,,':,::.lingeneral;_,this._manual'.'covers_the.:servicingof _the._enginei._and._associated!_,,_.:.

. ... _..,,_.,:..:_,,_._,.:!_._standard_!equipment,,,_ln,many_cases_;,engines,_are_supplied_,with_accessories,,,i,_,._. .,....ipm iq ith ppli• .. - :," :;;.... " .,,'..',,._,_:_,J_,and_equent_that_,'are_unue.:,to e?a cation.,_lf',serviceJnformation'is,;_.:_,_: ,... ,.,.".... ,..

. ,. .... .,_ever!requiredon'such uniqueaccessories;orequipmentit is suggested that;,',',.:the.Power.ProductsOperations.of Ford Motor Company be contacted. The

.................proper;informationwilleither be forwardedor the Service,Technicianwill beadvised where-it can be obtained..

.' "_ :.: ., :i:Theinformationinthismanual.is grouped in sections_,accoi'ding,to_the:typeof_:_:_'.;: work beingperformed. The.various:sections are!,inclicated!in_theiindex,::ln:',,_

".......... :,:addition;eachsection issubdivided to'include_topics_suchasdiagnosisand. ..... •....... "::,;:;_testing;>cleaning;'and,inspectionT::overhaul;::removal::;andfinstallationpro-

" : : : '::_:._;..:__:-cedu res; _:d_isassembl y..:_and_:assemb I,y,_:_pr,oc.ed_ures ;:'_,and _,;serv ice'specifications.

._ FORD MOTOR COMPANYFord Parts and Service DivisionPower Products Operations3000 Schaefer RoadP.O. Box 6011

Dearborn, Michigan 48121

The descriptions and specifications contained in this manual were in effect at the time the•book was released for printing. Ford Motor Company reserves the right to discontinue modelsat any time, or change specifications or design, without notice and without incurringobligation.

NOTE: The recommendations and suggestions contained in this publication are made toassist the distributor in improving his distributorship parts and/or service department opera-tions. Thes'e recommendations and suggestions do not supersede or override the provisionsof the Warranty and Policy Manual and,in any cases ,where .there may be a conflict, theprovisions of the' Warranty and-Policy Manual shall govern. '

Page 379: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3"'

, IMPORTA NT:S. EETY NOTIC Ei!: ::'i : :'di_p" r .....Ap -",.,.,_::...,,:.... ::.,,..... !ci..:_ propri,a'te_service_-_metho'drs_an : rope ;repair._procedares',are_essential _'_''. _:;".... "" _ ''

_'.,_., for the safe, reliable operation of all motor vehicles as well as the personal

......_" " safety of the individual doing the work. This Shop Manual provides gen- o_;i: eral directions for accomplishing service and repair work with tested, . .

_" . _,effective techniques._FoIIowing them will help assure reliability.

_ .... _ :._There. are numerous variations in procedures, techniques, tools, and. . ,.,.;_,,::__;......._ .... _parts for servicing vehicles, as well as in the skill of the individual doing _"

,...... ;, ,_,the work. This Manual cannot possibly anticipate all such variations and, " ¢_provide advice or cautions as to each. Accordingly, anyone who departs _:"._:! ::.ii_fromthe instructions provided in this Manual must first establish_th,a,(.,he"_-.,_:_. _,_compr.omises,ne_ther_._h s persona _safety,nor_the .veh cle:,,integrity_bi_;his_._: ' •....... __,

. .choice"of_ methods._tools.or:parts. "_ '

...... ' .,NOTES,' CAUTIONS;AN D.WARN INGS "._;As you read through the procedures, you will come across NOTES, CAU-

:_: ' ":"TIONS, and WARNINGS. Each one is there for a specific purpose. NOTES....._ _ _give you added information that will help you" to complete a particular

._-procedure. CAUTIONS are given to prevent you from making an error that.. _ could damage the vehicle. WARNINGS remind you to be especially careful

,.,:_,_: .:- _i:in those areas where carelessness can cause personal injury• The follow-. _,;ing list contains some general WARNINGS that you should follow when

youworkonavehicle.

_.'_'_ • Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the vehicle.

• Be sure that the ignition switch is always in the OFF position, unless otherwiserequired by the procedure•

• Set the parking brake when working on the vehicle• If you have an automatictransmission, set it in PARK unless instructed otherwise for a specific operation. If you ::havea manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL "(engine ON) unless instructed otherwise for a specific operation. Place wood blocks(4" x 4" or larger) to the front and rear surfaces of the tires to provide further restraintfrom inadvertent vehicle movement. :.

• Operate the engine only in a well-ventilated area to avoid the danger of'.c_bon.,.,..monoxide.

• Keep yourself and your clothing away from moving parts, when the e.ngine is running,especially the fan and belts•

-• Toprevent serious burns, avoid contact with hot metal parts such as the radiator,exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose _:_'clothing before beginning to work on a vehicle. Tie long hair securely behind the head.

• Keep hands and other objects clear of the radiator fan blades. Electric'cooling fanscan start to operate at any time by an increase in underhood temperaturesl eventhough the icjnitionis in the OFF position. Therefore, care should be taken to ensurethat the electric cooling fan is completely disconnected when working under the hood•

Page 380: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

SECTIONTITLE .... PAGE • SECTIONTITLE PAGE

• . ..... PART1 BasicEngine.................................. 1-01 PART5 StartingSystem ........................ 5-01. PART2 IgnitionSystem .... '2-01 PART6Govem0rs............................... 6-01

PART3FuelSystem ................................ 3-01 PART,7,CoolingSystem...................... i ...... 7-01., ,;_ 'o PART4ChargingSystem....: ........ ......... . ..... .4-01 ,_PART8Specifications..:............................ 8-01_

' Part 1 Basic Engine

SUBJECT PAGE SUBJECT PAGE

IDENTIFICATION 1-02 OVERHAUL

DESCRIPTION 1,02 ...... Cylinder:Head.... 1-17DIAGNOSISAND:TESTING ", '. : .,.. _, Valves,.,..................................,............._.:. 1-18

CamshaftLobeLift ............................. 1-04 .Crankshaft............................................ . .... 1-19'.L

.............. CompressionTest................ ................. 1-04 FittingMain.or,ConnectingRod , .•HydraulicValveTappet.......................... 1-06, , .-. Bearings,withPlastigage_,., 1-19Positive Closed-Type , , , Pistons;;Pins and Rings .... : .................. 1-20

• - VentilationSystem. "' 1-06, _.Valve Rocker'Arm' ' • ' 1-21.CrankshaftEndPlay ................................ 1-07 , .:PushRods .............. _......... ........... ,.... 1-21

• Rywheel'FaceRunout .... 1-07 CylinderBIock............................... 1-22CamshaftEndPlay .......................... 1-07 ADJUSTMENTS

CLEANINGANDINSPECTION ValveClearance............................. 1-23intakeManifold.............................. 1-08 REMOVALANDINSTALLATION

ExhaustManifolds........................... 1-08 CrankcaseVentilationSystem......... , ....... 1-24ValveRockerArm ........................... 1-08 " ValveRockerArmCoverandPushRods.................................. 1-08 RockerArm 1-24

CylinderHeads.., ..... i._...... .: i. ::.!. :, .i. :.. 1-08 Manifolds. .................................. 1-25TimingGears 1-1i CylinderHead............................... 1-26CrankshaftVibrationDarfiper._._.i'!_:i .i i,_...... 1-11 ValveSpring,RetainerandCamshaft ................................... 1-11 Stem Seal ................................ 1-27Crankshaft .................................. 1-12 Valve Tappet ................................ 1-29

Flywheel .................................... 1-12 Water Pump ................ ................ 1-29ConnectingRods 1-13 CylinderFrontCover 1-30o,,.oo.°_,, o, .,,,,,,,,, ..... ,,.,,,,,,,,°,,,,.,,, .....

Pistons, Pins and Rings ....................... 1-13 Front Oil Seal ............................... 1-31MainandConnecting Camshaft................................... 1-32

Rod Bearings ............................. 1-14 Timing Gears ............................... 1-34CylinderBlock 1-14 CrankshaftGear ............ : ................ 1-35Oil Pan ..................................... 1-15 Core Plugs .................................. 1-35Oil Pump ................................... 1-16 OilPan ..................................... 1-37PositiveClosed-TypeCrankcase OilPump ................................... 1-37

Ventilation System ......................... 1-16 Crankshaft Rear Oil Seal ..................... 1-37Main Bearing ................................ 1-39Connecting Rod Bearing ...................... 1-40

Page 381: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

f Part 1---Basic: Engine:

'i}!:!:: 1 REMOVALANDINSTALLATION(Cont'd) _ _ni_di _, i _/ Pistonsand;ConnectingRods................. 1-40., CylinderHead .......................... i .... 1-48

!:i,."_'i, i|. Crankshaff._i'. ........................... ,,...,....... 1-42 ValveLifter ................................. 1-49 ....._":

_!"_!" !t CamshaftBearing ........................... 1-44 Oil Pump ...................... _............ 1-50 ,_/

_!, ' i] Oil Filter "'ii' ................................ 1-45 PistonandConnectingRod ..... •.............. 1-50 : . '_,_.....il;!;!; _ _:| DISASSEMBEYANDASSEMBLY CylinderAssembly ........................... 1-51

,i;.:_ :__ ................... 1-45 CyhnderBlock............................... 1-51 ' i

DENTIFICATION ', ..... DESCRIPTION":

• " ,AnldentificationDecal,,is_affixedtothe left.side. The.Ford4.9 Liter six-cylinderengine is avail,of the rocker cover of the engine. The decal con- able as an engine assembly or a complete ready-tainstheengineserial numberwhich identifies this to-run power unit. In addition, a full range of op-unitfrom allothers.The model numberandS.O. or tional equipment is available to custom tailor thespecial options determine the parts or compo- engineor power unit to individual requirements.nents required on this unit. Use all the numberswhen seeking information or ordering replace- The cylinder block is manufactured from castment parts for this engine, iron using the Ford-pioneered precision casting

v. process. This process provides ultra-lightweight_ designwith a maximum of strength and rigidity. .; Special design features of the cylinder block in-

cludeseven main bearingsand full-length,full-.... ___:`_ " circle water jackets. The seven main bearings

providea rugged "foundation"for extradurability'and a smoothness of operation comparable to _many V-8s. The full-length, full-circle water jack-ets help eliminate hot-spots and provide moreuniformcylinder wall expansion under heavy-dutyoperation.

.,,The precision molded, cast:alloy iron crank- '

shaft iscarried in seven replaceable copper-leadalloy mainbearings. Crankshaft endthrust is con-trolled by the flanges of the No. 5!i'main bearing.

_>T, .

The aluminum alloy piston hasL_ree rings; twocompression and one oil control. The autothermic,semi-dishtype camgroundpistons.givelonger life ' ,.

:..with a minimum of maintenance. The connectingrods are forged steel and use replaceable copper-lead bearings.

Page 382: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• DESCRIPTION (Continued),

• ".........'presSed;,intp'_,the:,block,,_The_camshaft'"is_;_supp°rted';by_,_four..i:bearings:.o.,.=;_.,-,.A,chamber,(heatriser);castintothe intake.man-_.':.... ,,.. ,.'- ".i .,.,,:,.1_!_,_'!_'_:. It;is_driven_by_gears,:from:;.:.:..!-:,ifoldbetween,the'carburetonand_exhaustmanifold."_,.,.__.,, ._..:ii: ....._:_:`_.;_```_?_`_;_.;`_`_the_cra_kshaft_a_h_h_a_ft`_e_d_`_a_', . p yiS';cOht'r'0I'_d'lSy"._-....provide','theh'eatto vaporize,-the incoming 'fuel..... ,ii

• ..... :a plateboltedto.thefront of the block .Thedistribu-.;, charge.until the engine:reaches._operating• • tor, locatedon the left side of the engine, isdriven temperature.

" ' • , _ , . , ' .. ;': ......:,.-/nese engines_are',_equppea':wlm, a pos zve, . _,,,'-...._-:by'agear, onlhe,camshaft The'd strbutor drves, . .;,_: ' " ....... '. .._ . ;=-' ..... "therotor-type odpump through anntermedate cio d," _v ntiiaton s tem_wh h',-r " th _"%• ,drivA_h_ft .... ' . ..'..,..., . se mjpe e , ys c e ec[s e .:

, ...... _":-"" " . ,": . - .-'.=-':, crankcase vapors to::the_,'intake,manifold for' , ,, ..",L:_'The,cylinder,.,head:assemby:contains;.the fue .... combustion.. _ ......,

.,...-intake,:passages .the-valves and the individual .......... ' ,], _." _ ..,. ,valverocker,armasse_mbl'ies.,Valveguidesarean _:_'%_''_'_Thei4",9E!p.ower:un,it_'is"a:_q°,mpletelready't°-run'

.... --:integralpart oftl_e head; ioloti_nal hardff_'celdin-':- : engine:mounted:,on.;a:doot-'type:frame: Included• t_k_ _n_ _=_h_,,_v_ v,=_,=_ n_,_= =_,',n,_,=,_°_": ;are radiator;pushef.o__ijIler-typefan',:powertake-.

...... , . .... J -,, ,; .' - ,,. - " - ................. off' nstruments;'thrott e'_:choke;'a r:Ceaner, ex-• " " _:""m,ome'neaas:..zne,nzaKe_ano.exnauszva,ves'are;'" .....ha' t e nd:a sl_eet°'metaiShroucl"encl' in "

,."_',::::actuated,thfeugh;hydraulicvalve,liffers;:androcker: '.'.",, us p!p ,.a , _ . .,: , ,. ,,.os g,..:,•..... ,arms.,.Rocker, arms.areindividually, pedestal_ , the tronz,rear and top orunzt.

mounted.

• . ,, .. ...., ,,

"" " " ' _ / I '"

¢

A.2176-2C

Page 383: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

DIAGNOSIS, AND TESTING..

_:".,:, ":CAMSHAFT:,L'OBE_iLIF,T,. ,:. _.-: : _,. : "' COMPRESSION,TEST:::":" : ...... '

,:: ._-_, I_:_'";" .,,:,:" -.. 1. , _, . . " ,,,,.,_ ...... '-'" .'.-. :'; ,:'" "' :,":_ ';_.._:_',_...... _:' Check_the'hff'ofeach"lobem'consecuttveorder" _ ';:'COMPRESSION"GAUGE:CHECK""_ ''" "_ : "_" and make a note of the readings. The followingprocedureis to be used when

._1. Remove'.theair cleaner. Remove the heater checking compression: .: ._:... -i. hose and crankcase ventilation hose, if so 1. Be sure the crankcase oil isof the correct "

i': _ equipped: Remove valve rocker-arm.cover, viscosity and make sure that the battery is2. Remove.the rocker arm. Use the adapter for properly charged. Operate the engine for a

ball end ;ipushrods. minimum of 30 minutes at 1200 rpm, or untilthe engine is at normal operating tern-

• ,. 3. Make sure the push rod is in the valve lifter perature. Turn the ignition switch off; then re- "• .: socket. Installa dial indicator so that the actu- move all the spark plugs.

ating p0int of the indicator is in the push rod

.:i!:::_!:. .socketand in.thesameplane as thepush rod 2. Set the carburetor throttleplat:es in the wide_' ,"."movement.':. - . • .... : open:,position:,.,• .,i_.

4. Connectan auxiliarystarter switch inthe start- 3. Install a compressiongauge liT;No.1cylinder..._.. ._.ing..circuit._Crank.the:engine.with:theignition; 4: Install an auxiliarystarter switchinthestarting. ::

switch OFF. circuit. Crank the engine (with the ignition'_:-,._ 5. Zero the_ial indicator. Continue to rotate the switch OFF) at least five (5) pumping strokes_,:,'_-._.... _..... cranksh,_ftslowly until the push rod is in the and record the highest reading indicated..... .!, fully rais":_dposition. : Notethe approximate numberof compression

": strokesrequired toobtainthe highest reading.•' • 6. Compare the total lift recorded on the indica- '

_ .. tor with Specification. 5. Repeat the check on each cylinder cranking ,_the engine approximatelythe same numberof

_' ..... 7. Tochec_the accuracy of the original indicator_;. . compression strokes.- reading,:bontinueto rotate the crankshaft until ".':i:.

_'_ :" the indicator reads zero. If the lift on any lobe " " ','. ," J " -is. belowspecified.,wear_-I.imi_ts_..._,-the

_, camshaft and the valve lifters operating on Test Conclusionthe worn lobe(s) must be replaced. The indicated compression pressuresare con..... :i_!

8. Removethe dial indicator and auxiliary starter sidered normalff the lowest reading cylinder is ...:_..switch, within75percentof thehighest.Referto thequick

. reference chart for pressure limits betweencylin- ...9. Install the rocker arm.' ders. Variations exceeding 75 perc6nt implies an

_ 10. Install the valve rocker arm cover and the air improperlyseated valve or worn or broken piston ,,cleaner, rings. If one cylinder reads low, squirt approx-

imately one tablespoon of.engine oil on top Of thepistons in the low reading cylinders:,Repeatcom-

_.,__ DIALINDICATOR pression pressure check on these,cylinders: :'

8o a. Ifcompression improves considerably,the

l__i//..,o _ piston rings are at fault.DIALINDICATOR !; _,,_ b. If compression does not improve, valves

BRACKETRY aresticking or seating poorly.D78P-4201-F _ _(_ ", 5o _.,,,"

/ _h__cuP SHAPED C. If tWOadjacent cylindersindicate low com-i_ / _' ADATERTOOL _ pressionpressures and squirtingoil on the

_ _,.,._.__ pistons does not increase the compres-

sion, the cause may be a cylinder headgasket leak betweenthe cylinders. Engineoil and/or coolant in the cylinders couldresult from this problem.

Page 384: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

_:, .".... .,' " 1:05,,,,_:" '..." , .;. "_"_ -.' :' '_":_". ': "":;"_;,_.'IBASIC:ENGINE;._!'.,_.' ." ".

......... DIAGNOSIS.:,AND TESTING .(,Continued)] .... , ........... .,.

i- ":;,._,,,..._-,:;..,;.,........ '_'" _:,:::,:'_,'.,_After,,dl_ecking_the_compr,ession_pressures,in:all,_,:,:_",'_kPa'_,(:105:'psi):"Since'.the_,.Iowest_,cylinder;_r.eading:"T'',", _._,cylinders;: the highest.reading,'obtained.was 965. was,689 kPa(tO0 psi),.the engine is not within

• "• .... " , '. kPa,(140 psi)_andthe lowest:pressure.reading was.' : .'specifications:andthecompression is not consid-r' :_'"" 689 kPa;_(lOO,psi):_Bylocating 965 :(140) in:the_,.. .ered satisfactory..

, " _-_'_",.,Maximumcolumnitisseenthatthelowestallowa_ ........... .... ,. :_.ble:pressure •listed in the Minimum column is 723 ' _ 0,

• .'.%..., .. . .. ,, ' - ' * ,

p

,. , ,,

'-, .......... :.',._ -.._.Maxlmum:._,, _'.Mlnlmurn J._.,..=Maxlmurn,_ ..... ..,:Minimum; _', ,,,.,Maxlmum_._,;: ,',_..;'Mli_lrnum_..;_;:,:i__Maxlrnumi,_,.. .'?Minimum.. IPSI .PSI PSI ' PSI , PSI. " " '-. ,.,PSI..._ , , .PSI . .PSI _,

•" 134 ; 101 164 _" 123 - ' ' -;194. _:,' .',.".._145 .'.'.."'.' .-i: ._...224"".. -" 168.... ,,, ,

136 102 166 124 196 147 " 226 169

138 104 168 126 198 '..148 " ' 228 171

,..,_ ................. ,_...... 140 105 , . , "-170 127 . 200 '• ..... :_"i50 "' .. " ' '230 ...... .172142 •'107 172 129 • 202 . -151 ' :. '232 '. 1•74

144.'. - '108 _ ' 174 . 131 . _ ' ' 204 ' 153' ' " '. 234 ' 175

146 ' 110 176' ' ' " 132 206' ' ;" '154 '' ' 236'' "" .177I

148 111 178 ' 133 208 ..... 156 "" " _': "'" "_'"238 ' " " _...... "1'78

150 113 • 180 135 210 :: 157 240' 180

152 114 182 136 212 158 242 181

154 : 115 184 138 214 160 244 183

156 117 186 140 216 162 246 184

158 118 188 141 218 163 248 186

160 120 190 142 220 165 250 187

162 121 "192 144 222 166

CAIOO5-2B

Page 385: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.L,":/;-_,1:;06_i:;';_'_ _ ._• -;'.,_.'°_'.: _'_-'"::, ="_';.:_;'_'-_BASIG_ENGINE_!",:.:._'.__'."_.' " . • , . 1-06_ ',:

....DIAGNOSIS.• AND .TESTJNG(Continued) ..... '

.;HYDRAU LIC;VALVE;.:T,APPET.,. ......... ' .............. .'. ". POSITIVE.C LOSED4T.YPEI_VENTI LATION_;_I_,.. . . SYSTEMi,;:r. ....

...._._rHydrauli(;:tappet:.noise.may;be,caused,by,a.ny-of{ ....... : . . . . _..the following: A malfunctioning closed crankcase ventilation

.... i. system may be indicated by.loping or rough en-_,_.• : -1. Excessive collapsed tappet gap. gine idle. Do notattempt to compensate for this ". •_,_"_. 2. idle condition by disconnecting the crankcase. " Stickin_i tappet plunger. '_:

r• 3. Tappebcheck valve not functioning properly, ventilationsystem and making carburetor adjust-_ _'_ ments. The removal of the crankcase ventila..... ,..:,_

, 4. Air in .lubricationsystem, tion system from the engine will adversely ' :'_::_5. Leakdo_n rate too rapid, affect the fuel economy andengine ventilation

%_ with resultant shorteningof engine life. To de- ;6. Excess_._evalve guide wear. _,terminewhether the loping or roug•hidle condition •

ExcessiV_!:collapsedtappet gap maybe caused is caused by a malfunctioning,cra_kcase ventila- •..::.,tion;system;:performeither,_of,'._th_:i;!bllowng:,".,:'-?..-........ :,' ' _:''r

i" adjustment; or wearof.tappetface,.pushrod;'rock-.:_, Functional:Check _"_......erarm, rocker arm fulcrumor valve tip. Withtappet

'.collapsed,checkgapbetweenvalve,tip and rocker;.... 1. If the.PCVvalve rattles when shaken;recon-arm to determine if any other valve train parts are nect it; if not, replace it.damaged, _orn, or out of adjustment. 2. With the engine at idle, disconnect hose from

:,_ Asticking_tappetplunger may be caused bydirt, air cleaner, and feel for vacuum,at the hose. ,.,chips, or varnish inside the tappet. The sticking • Some vacuum, system is OK.can be cbrrected by disassembling thetappet and

• Novacuum, eitherthe system isplugged orremoving the dirt, chips or varnish that is causingthe conditioh, the valve is leaking.

A tappet _heck valve that is not functional may CRANKCASEVENTILATION REGULATOR .;i:'_, be caused by an obstructionsuch'as dirt or chips VALVETEST _':_, preventing.i_tfrom.closing,when,,thecam,.lobeis

liftingthe _tappet,orit may be causedby;'abroken Installa known good regulator valve in thecheck valve spring. crankcase ventilation system. •;:_

,:,i

Air bubbles in the lubrication system will prevent Start the engin e and compare the engine idlethe tappet from supporting the valve spring load condition to the prior idle condition.

and may be caused by too high or too low oil level If the loping or rough idle condition remainsin the oil pan, or by air being drawn intothe system when the good regulator valve is installed, thethrough a hole, crack, or leaking gasket on the oil crankcase ventilation regulator valve is not atpump pickup tube. fault. Check the crankcase ventilation system for

If the leakdown time is below the specified time restriction at the intake manifold:or carburetorfor used tappets, noisy operation may result.If no spacer. If the systemis not restric_!6'd;further_en-other cause for noisy tappets can be found, it gine component diagnosis will hage.to be con-

....should be replaced, ducted to find the malfunction. :'_

Page 386: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

. •, ._____l-fl7Y._". ' '

i

• DIAGNOSIS AND,TESTING (Continued) .......

I°' ....... "' "- ' CAMSHAFTEND"PLA¥.;'_ ' " : ", ' '_'_CRANKSHAFT,;:_END,!P.EAY'_._:,,._:,,. ':,

" ,_,."._- .i_'...,._i :the:crarl_sl_hft:'toWard:the feai__bl;_tfie°'_,,, : ..Push the camshafttowardthe rear of the en- " :• engine. . ..... . . . . .':. -'gine..Install'a.dial indicator sothat the'indicator

: :, :....'_-'."" .::2:.,:'lnstall,adialJndicatorsothatthe.contactpoint..: ;"'_ ,'point:isr,on_the'camshaffsprocket_attachingscrew : .: '.... . ...:,,-:i '_,,'!-_,--:rests.againstthe,"crankshaftfl_.nge!;hn'd_,'tl_e,:,,; _...... _:or-!gear-'hub::,Zero_,thei'diaHndicator.:"Position, a. _ . ...-_::1

. .., :::._...,.:,,.::,::.;,_:indicator.axis_is:parallelto_the:crankshaft.axis/•:_,,",.:,-,-_";;.:large:screwdriver.betweenthe;camshaftgear:and:: _i .. :................... - ::.,::.:, .::the block:'PUll:thelcamishaft:f0rWard!andrelease it...-.,.3._;.>zero.,the:dial_'.indicator:,p,ushi:the'_crankshaft.-.i:,i:/.?,,I>Compare_the:.::dial;_ind.(cator.;,r,eadingwith 'the ....:,";. :.forwai'dand note:.the:ireading0n.the dial".: " - .... '"specificat[on's. ....."" .... :i........... :.. " " ' " _]

_:_4:_:_i,`_f_t_eendp_ay:ex_e_dsthewear:_imit;_'rep_ace`_'i_2;._` ;`_`_`_`;_:.._;2;_``_A_I_`c_:;:_`_:_ ._. "!:"__':_;_"Hilthe:endiPlay"iSlexcesSivi;_check!ihespacerf°r' '.ii _!.i.:,,,...L;.,.the,thrust.washers.:lf_the,endplay,is.les,_than_',i _::z'cor,rlectdnstalla_tion_,:before_it}!s;.:removed.:If' the i_

........._'.the'.,minimumlimit_inspect_:th•e)_th_ust,_gearin_g'_2i; ','.::aM_,_spacemis._correctly;,finstalled_._replace',.the thrust '' _":'...... .__'-_:'._'_"_"::'::_'a"e°_f°',,_cr"'_'"'_°,_"_"'U_,':'."_'"s,,_°'-.'u"'-_'_,/::-,. . ,plate,',,:, , :._'".: ,._. ': ::, ,_._'_, ,;_. . /.: ,. :,., .:.' " :

"Remove.the dial indicator. /. " "

•," FI..YWHEEL FACE RUNOUT ' ' ._..::.,.._,,,_,.:....,:,....:_.,._.,__.,....._,._-,,._:,.:..

.: • .....:":_ .:"":'_"dnstallia'dial,._ear.slaoa...s,h nin't theindicat°rs°'that,flywheelface.-Turnthe indicatorthe flywheelP°int'..... I " .":::'?,._',,_,,'_'i:.:'':'_:';::'_',_,'_'__'_':;' ': "..........:_"::::_;''_'=_'_''_:_'=_....' " :'"'""'_ " :_'.... ."" .'........................ ' ' "I "_"' ":_'_'_:_:_ _!'':'_'"": • "', '

,' ' _. • _ _!,, "::_ ' :_.. ,?':i21. , ::;:_: _'_• : .: ;-..flywheel-,runout...... ;,, . , . _.... _ .....

..?',:lf,theclutchfacerunout,oxceedsspecifications,, __."'removetheflywheeIand-check.forburrsbetween,_:........ :....:.,- - •

,'.'>".;:::._.::::theiflywheel:,,andthe;faceof:thecrankshaftmount-I ..../"::_' i':"' '::' i ,..,,ingflange:-Ifnoburrs exist,check,therunoutof the_::.!,i ...=•icrankshaftmounting flange. Replacethe flywheel :. 1.PUSHCAM TOREAROFENGINEormachinethe crankshaft-flywheelmountingface. 2.SETDialONZERO .

tions.ifthe mounting flange runout exceeds specifica- 3.PULLCAMFORWARDANDRELEASEA3olo.A '

_i, - INDICATOR -: BRACKETRY ..... (-:-

201F

DIALINDICATOR..f_.Iill /_/'_. a complete engine overhaul; therefore, for partialA9621 oI A ,'D78P-4201.G//(_,_._,_ engine,overhaulor parts replacement, followthe

pertinent cleaning or inspection procedure.

Page 387: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i

I' _''-_:i:1"0,81"_'' ":-_':' "-_'"" •.......' :" " ......,': ;' - ,"_:....:BRSIC,.ENGINE_.........:__', . 1-08_:

!

CLEANING AND INSPECTION (Continued)

Ni ..... i .... :::'_'INTAKE:MA FOLD:L:.:_,,.._,'.,,::, :'..-'_""_..::. : , .'.' PUSH:"RODS_::.':"'.,"'..... . '"-. • -:. ,

_Cle'aning................ " " Cleaning! Removeall gasket material from the machined Clean the push rods in a suitable solvent. Blow-..surfacesof the manifold.Clean the manifold in a out the oil passage in the push rod with com- '.... _'_

_i_suitablesolvent and dry it with compressed air. "i_,. I pressed air. ,_ _,,_

Inspection _': Inspection

Inspect th_;_manifoldfor cracks, damaged gas- Check the ends of the push rods for nicks, •'iii_

i ket surfaces;_or other damage that would make it grooves, roughness or excessive wear. ..;ii' unfit for further service. Replace all studs that are The push rods can be visually checked for - . .:_ stripped or o.!herwisedamaged. Remove all fil- straightness while they are installed in the engine ._" , .

nngsandforeign matter that may haveentered by rotating them with the valve.clQ_d. They also .,_:as,.a.r.esult:,of_repairs./............. ,,... _.can be-checked with'a:dial:qndic_ri"::: , _., .: .... . "i."::"';:!

DIAL F'_ HOLDING FIXTURE,_.INDICATOR _ /I \

.... _: WITH BRACKETRY_ f/,,<_r; o,'_'_ /_ \

"E ""_ TOOL-420,-C3¢:"'_ "3_ //'/ ,3_ "3,::,, XHAUST!iMANIFOLDS::;, PUSH ROD k_.'o %--oJL/._._ /]_r _ 1.

Ceann,:_. Remove,all}gasketmaterial from the manifolds•

I _:Inspection' :_:"_" -- A9623-1A

Check the_iexhaustcontrol valve for freedom:! frombinding_throughoutthevalve travel.If neces-,sary, free the shaft with exhaust control valve

..::solvent.Ifthe-solventdoes n0t'eli_ihbt_ ttl_lsind--_:_ingcondition, replace the component parts. • " -' :.

Inspect ihe manifold(s) for cracks, damaged CYLINDER HEADS • , ':_'....,,.gasketsurfaces,or otherdefectsthatwouldmake Cleaningthem unfitfor furtherservice.Inspectthe cylinderheadjoiningflangesofthe exhaustmanifold(s)for With the valves installed to protectthe valveevidenceof exhaustgas leaks, seats, remove deposits from the combustion

chambers and valve heads with a scraper and"a wire brush. Be careful not to damage thecylinder head gasket-surface. After the valvesare removed,clean the valve guide;boreswithavalve guide cleaning tool. Using Ci_ning solvent

VALVE ROCKER ARM to remove dirt,grease andotherdeposits',clean all

Cleaning boltholes. .,_.,.:Remove all deposits from the,valveswith a fine :'

Clean all the parts thoroughly. Make sure that all _;_wire brush or buffing wheel. ....oil passages are open. •,:

Make sure theoil passage in the push rodendof Inspectionthe rocker arm is open. Inspect the cylinder heads for cracks or exces-

Inspection ..,' sively burned areas in the exhaust outlet ports. :.i:,.!iCheck the cylinder head for cracks and inspect

Inspect the pad at the valve end of the rocker the gasket surface for burrs and nicks. Replacearms for indications of scuffing or abnormal wear. the head if it is cracked.If the pad is grooved, replace the rocker arm. Do .!L-_not attempt to true this surface by grinding. The followinginspectionproceduresare for a

cylinderheadthat isto becompletelyoverhauled.Check the push rod end of the rocker arms for' For individual repair operations, use only the perti-

nicks, scratches, or excessive wear. nent inspection procedure. -

Page 388: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.CLEANINGAND.INSPECTION. (Continued)

• ,.-,_._: , _,:_,,_ _ ,,.. ........ ,,

...." "' ....... • " ; .....n Measurethe valve.seat'width.'Reface_the'valve,,_'• ' • - _.Whe a,cylinder-headis removed because.of .....• ' . _,, gasket' leaks,,check,the flatness Of the cylinder..... seat(s)if_,the,width,isnot.,withinspecifications..

........ ., :.head gasket surfacefor,conformance.tospecifica. .VAEVES,, • -. • _,., -....' .:,,. .. ";:,_-_::',tons'_lf :necessar:y'to,refn shthe'cyl nder head" " ' _,. _'-.".-.:., "., -. _,.: - ._.' _........ ;" ...•, .... , .- . ...... " . ..'.,,_ne,cnuca_:,,nspec_onpo_nzsland'_toferancesor.

.... ,"gasketsurface:,donoz-ptane orgrmo on more , " ....",. ':: .., '. _ . :, . . , - ........ ,_,,.,:-.,._.,,;the.valve,are.dlustrated_Refer tospectficat ons for

.... :.::,.J.,than. 0,254- ram::(0.010 inch)"fr°mthe:°rtgmai._ ',:- wear. m ts:'lnspectthe.valve,faceand the edge of........ . , ".....gasket. surface ............ • _.._the.valve.head_for.,,:pits_';grooves,orscores::lnspect.,

. _ -_;;the stem.'.,for._abenL'condt on and_the .end of the

,__'.:.___,::stem.for,,grooves_ori;scor,es.;.Check_'the:valvehead ....... ,_"_.._..,_.for:,_signs:..-.of,_uming,.:oi'!.,.,er0sion;..:warpageand,',_'_:cr,acklng.:_Mmor,,_plts,_,_gr;ooves,-.,,_:etc.,,..,may,,be re-.,.... _` , .- - ;___--_"_,=_ ...... . . . . • . .'

_-".. ' ,_'_-,;'" : ,'_L-::.,,,' .....,.. " . _.."o--_ _.:_...... ' _ ," .'",',,_moved._DiscardSeverelydamaged;valves:',,_',o._.,.._..-

' ' J "[i" _' .,, "::._:C_,;,. ® .VALVE. FACE RUNOUT '," ' " " " "

® .... :,,._ceedthespecifiedwear-limit,If the rur_outexceeds ,,,, . ._,.-:,,:,.::,the_wear_,imt;,_;the,.,._ave_shoud,_be_r,eplaced-or • •

' ,.''1 1 V// " ,.',- '.. , SERAIGHT EDGE,r,,._t . - . . • ... : refacedas,outl"'_' ';: "-;"" "'ned_underRefac""""_";""_";::.......'""ng_Vra:_ ves n.this '• "t '17// '' " " "ROTUNDAMODEt_'III I1 I/ / / .... 014-00319 _ _,I section. .._ CHECK DIAGONALLY _ '_-

._ _'CHECK ACROSS CENTER A2895-1B -"VAI'VE_STEM_':-CLEARANCE.::","!;::; " ",:;

....... . ""- _ :_-..__':Check'the::valve:stem,,to.,valve_'guide:clearance........ VAEVE,_SEA:rRUNOUT...... ' ';' "" _" _'_:':_ofeacb;valvein;its,respectiVe;valve;guidewiththe

• ':.. ....... "-. toolshownior_:itsequivalent.:Useaoflatendindica: ",;.- Check'thevalveseat,runout with an.accurate tor.point., ' ," .. _ ' • ' " . :,

- :,..,";,:,:_,:;i,lnstallthe ion_thewave stem Unt is_fully...... _'.,........_ ._ ,_l.."_:-:,_gauge,Follow_the'instructons Ofthegaugemanu :,.,. .,too, ;- . ' . _t- , _,-'_.,'.,.... _facturer.-:lfthe:runout;exceeds_.the,wearlimit,_.re-; -.seated,and tighten the knurled set screw firmly. -

face the valve and valveseat., Permitthevalve to drop awayfrom its seatuntil thetool contactsthe upper surfaceof the valve guide.

VALVE SEAT DIAL INDICATORRUNOUT GAUGE ,_ D78P-4201-G

D81P-6002-E \

-- _,_ _.._:,

( 3/ c)

DIAL . .VALVE STEM INDICATOR ''r"

CLEARANCE TOOL BRACKETRY'A9624-1A T65T-6505-H D78P-4201 -F A9625-1A

/

Page 389: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,,.:,._I;_I-'10_,,_:;_'._,Y.-,-! , ..-..;', ;: .",',,; ....,,. : i,,_ <_<j<_BASIC.'_ENGINE_,_':_;.':_, ....... " ' 1=10%" • • ' i::.'-_<;<,:,,,. _ i ..... ..... " , :i,:,.,._,' ',!',_:._'>'._"i_-:,.

.CLEANING AND INSPECTION (Continued) .,.

. .., .,..,:.,..,_:::Position.,the_dialindicator_witb',,itsfflat'tip;against,,_,:_.:o;"_::,VALVE_SPRING!SQUARENESS',",:,,_;,%; ,,. _,_,,.:' ' ....,: : ``:_:_;::`_`the_center_p_rti_n:_f`;th`e..t_!s_spher_ica_`secti_n;at_._;`_!_`_;;_.:_.:-:,, ' ', _ " .. - :' :"".?_. :, :"; 'approximately_90'degrees"to'the'valvestem'axis_.'''..... ""Check eachspring forsquareness Usingasteel,_,,,;_,,: , Movethe toolback and forth in linewiththe indica- square and a surface plate, Stand the spring and_;/, ,- tor stem. ,;Takea reading on the dial indicator , square on end on the surface plate. Slide the_,_.,:..}. _., without removing the. tool from the valve guide,,_;,, springuptothe square.Revolvethe springSlowly ......:.._,, ;' %<:'i_,,_.... i-,; , uppersurface. Divide the reading by,two, the divi- andobserve the space betweenthe top coilof the .....

,', sion factor.tfor the tool. spring andsquare. If the spring is out-of-square..... '....... more than specified,replace it. "_ii...... _.... VALVE S_RING PRESSURE

_ _'_;_ Follow the sameprocedure tocheck new valve_': ' _ Check.t_e valve spring for proper pressure at springs before installation.!;>_...:,.,'_{,/.i the specified spring lengths. Weak valve springs ,: :.;;_,_. :ill cause po.9_,performance; therefore, if the pres...._ii'_, I _"::,,', sure of ar_"y,springJs, lower;than-.the,,wear,limit,> . '_ ' :_';'

:_:_!;:[_;.,, !_replace_the-sprmg:'.', .,', ' • , , • i, "-!,!/_,;,,:,_',._',:_. _.i,:.:""APPLY TORQUE:.DtqTIL _"-_)"'_'_7 _ / i i...... -'.. CLICK IS HEARD ._'READ _ "_....,_'/ ....i:"_'_;i_ " TORQUE WRENCH'AND -- / /_ _ //

" :,; MULTIPLY READING L_ /_. _ ' ¢

.... •_ CHECK

, , " \i._ SPECIFICATION

_' ....... // VALVE SPRING• ...... // TESTER

VALVE ,.:_

/ t _ I_L-rcJ_...,...._ SET KNOB TO . ._---/ ! _ _ _COMPRESSED

t _' ,,-,,-, • _ LENGTH OF

_._ SPRING CLOSEDCOIL END

A9077-1A DOWNWARD A9248-1A

,>_._,..... -t,-

Page 390: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:CLEANINGANDINSPECTION(Continued) I.. _. .

..: ,_:-"?YDRAULIC;VALVE:.LIFTERSJ::'...:_.,. ,...',,.',",_-. ,. . .

" ; ,!:i:"" "' " ... , .. ..., .i.'..r..-"'"':"i"r_:'Cleaning",..,.:,:.:....'::. - :..:::" " :'"',;"Thevah/e_liftera.sse'mSliessho(Jla'be'l_e_t ......... ..propersequence:sothat'theyCanbe installed-in........,:.Clean,the,oilseal'contact'surfaceon thecrank-

; . . , ..... shaft.damper_orsleevewith.solventto remove any... .,.-... ..._.theiroriginal Position..-Inspect.and,test.each lifter : ,.' :., "'-' , ......, _: ,_;_,separately;:soas not'.to:intermix.the.internalparts:,':,;,_._>...',_:_.,cOrrosior_;.sludge_or.varnishdeposits.E-xcessde-,

•: -.. -...: ,, :.;_ ....._.lfany,part of.the lifter,assembly, needs repla¢- _.,. _,:.: : ."poSitsthat are -nbt.'readily,remqved w th so vent :.•.. . :; ". ing;.replace •the entire:assembly. : • .. ......: ....,......:mayi be:.removed.:with; crocus.,cloth.:Use crocus

• , ', - :?.cloth_}to.remove:any_shar,p_.edges,:burrsor other" .:".." . " .,':Cleaning:." : . -' ' i. •' ."i .... ._! "._impeffe'Cti0ns!'_hi61_:::r:night_da_age"theoil seal

' ' .............._..... ,..........Thoroughlyclean alrthe:parts:in"cleani'ngSol-.-:": ,_','.during;ins,taltation_.or;ic.ause_pr,ematureseal, wear.' :.:_ " i' went.andwipe_them:w th-a"clean_ int-free' clothl° - ,,,,,'.....:_:,:.D0,_hot::.use!¢focUs_cl'0th_toithe"extentthat the

. " " -...... " .....:. "'"_"'.........."'" ::,.,,seal_iSu_a'ce_be_omes{polished,,,Afinelypol-, .. , . ............ " ,. ished.,surface, may_.produce,poor,seahng or

:"'" _':' '':"'q"I'%" .''': _:_ r'::'_:' _'' _ ::_ Inspe'ct:',the".J_)arts!:'andidiscard!.-"'the::entire".lifter"!i,,_',',._.,:fl::causelpremature.seal :wear;.!.:,,,...::.,,,:..,.:-,.. ..,......,

p ." ' . .:,.;....,.-,_:._.,,:.assembly'if.anypartshows pitting;'scoring,galling . ' Ins "........ ;-.,...-.._:. ,,.or evidenceof.mon-rotation.Replace:the entire., . " ection

"........ ,:.. "i :'assemblyif the,plunger isnot freein thebody.,The..... . Inspect thecrankshaft,damper.orsleeveoil seal•_ :. :,' ::;-;,plunger.should drop to_the,bottom',of:.the_'bodyby-,':'.:_",-:, :"_.surfacefo_.n!cks,,sharp:edges.or,burrsthatmight ..

":" _'. .:'_.its.ownweight when',assembled dry. ; '_..'_' -.., ...... ,,. _,._dar_a_le:i:the!i,<_ily:,s_ai_d_ring_.inst_Jll:ationorcause

• ' ; '- i:...._,.Assemblethe.lifterassemblyand check for free, , . - . ..... .... . . ................................. ,-:;ness:of operation'by pressing :down'on:thepush .................

.. :"rod,:cup.:qThe:lifters can also,bechecked with ai:.-.:.,.......:,.-,:.":,._:.'.:.:,:_.hydr.aulic,:tester,to;test.theleak,down_rate:,:Follow................

...... --,.,_..,:.'.-:.the:nstructions;ofthetest:unitmanufacturer or.the , ,:,:.CAMSHAFT _ .....

.. procedure. in .this,manual. ,.,..Cieaning'..and_.lns'pecti0n:",.,..:,i.,.;i : '.

....... ....::..:',:,._.Cleamthe:camshaft.'imsolvent_and'wipe_it,dry:,::..ii i.:. ......... ' , . Inspect the camshaft lobes.for scoring and.signs.

of abnormal wear. Lobe wear characteristics mayTIMING GEARS result in pittingin the general area of the lobe toe.

This pitting is not detrimentalto the operationofCleaning the camshaft;therefore,the camshaft shouldnot

Clean the gears in solventand dry them with be replacedunlessthe camshaftlobe lift 10sshascompressedair. exceeded 0.005 inch.

The lift of the camshaft lobes can be checkedInspection with the camshaft installed in the engine or on

Inspect the gear.,.teeth:for:iscores,,nicks; etc." • " ._centers".Refer to Camshaft Lobe Lift.Note the condition:;oftheteethcontact,pattern.:lf:" ! ' ' "..... ' .....the teeth are scored;:replace.the gears. ' ' Check the distributor drive gear for broken orchipped teeth.

Page 391: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

CLEANING AND INSPECTION (Continued) ._

.,,.............. ,., inspection::_.,.... ...

Sp j n f0• ' .,- In ect the main'andconnectingrod our als r_."'-'_,"Cleaning't,. ":cracks, scratches, grooves or scores.

:." Handlethe crankshaft with care to avoid ,_•" possiblefractures or damage to the finished ' Measurethe diameter of eachjournal in at least ..._._:_

_.J';_surfaces..Clean the crankshaftwithsolvent,and- four places to determineout-of-round,taperor,_..:blow out.a!!passages.withcompressed•ain.... undersizecondition.:,i_ Clean tl_eoil seal contact surface at the rearof' On an engineusedwith a manualshifttransmis- ,.;"-_,_,i._: the crankshaft with solvent to remove any corro- sion, check the fit of the clutchpilot bushingin the .

sion, sludge or varnish deposits. Excess deposits bore of thecrankshaft.The bushingis pressedinto._" that are n_ readily removed with solvent may be the crankshaft and should not be loose. Inspect

__;' removed _ith crocus cloth. Use crocus cloth to the inner surface of the bushing for weal or a bell- .• ;'_ remove a_i_/sharpedges, burrs or other imperfec- mouth condition. Check the ID of: t_b_!bushing. - :,:_";".;, tions,wh ch might,damagethe oil seal_-during_in-,.._-:.-Replace_thebushing.if it ,is.damaged_:0r,the:lDJs;;.'_,;,_' "-: ....-i-_ . ..i./__

_''; illatioh,or.'causepremature_seal;wear. Do not:'i;":".i,not'within,specifibatior_s:.:, _..... '; ':;, '....use..,crocus cloth 'to the extent :that. the seal Inspectthe pilot bearing,when used;,for rough-<

_i:i:_-...surfaces,'become:polished.,;A.,.finelypolishedi.,:.,,."ness, evidenceof overheatingorloSs of lubricant. ' 'surface may produce poor sealing or cause Replace if any of these conditions are found.prematur_i,seal wear.

Inspect.therear oil seal surfaceof the crank-:..? _i_- : shaft for excessively deep grooves, nicks,_,burrs, " ..... i., -;_ porosity, or scratches which could damagethe oil":" _' '_; seal lip during installation.Remove all nicks and' _:' burrs and polish the chamfered edge and oil seal

A V$ B _---- VERTICAL TAPER contact surface with crocus cloth.C VS D = HORIZONTAL TAPER

A VS CAN C) B MS D _ OUT OF ROUNO '_"_

CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL

PILOT BUSHING _ TELESCOPEGAUGE , ;y

A29o_._c FLYWHEEL A;tg07-S

?:_

FLYWHEEL

Insl_ction Inspect the ring gear for worn, chipped, or ...!Inspect the flywheel for cracks, heat checks, or cracked teeth. If the teeth are damaged, replace

other damage that would make it unfit for further the ring gear.

service. Machine the friction surface of the With the flywheel installed on the crankshaft,flywheelif it isscored or worn. If it is necessary to check the flywheel face runout, following the pro- ;.

,,,._-removemore than 0.045 inch ofstock:from the'-." cedure under Diagnosis and Testing.originalthickness, replace the flywheel.

Page 392: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•.._,_._,:_._;_.:,.,:,,"_1-13. :. 4_,, ''_ k' _ _r_ ' ' ' ' !':BASICTENGINE:*'_: "'" ";: ;'" '" ' ' '. 1'13 "

::CLEANINGAND INSPECTION (Continued)

O . ,. •• "_"'," " _ ::'.::_,:_CONNECTING:RODS ......< ,. ' " Twisted'connecting_rods'willnot c[eate°an,easi-', ._

/ig ' ": ....' ';: "_;" ...." ':":;":_;Cieani.... '" ly identifiable..wear_pattern,but,badly:,twisted_,rods,:,:_,,_.i ' " ' _ ' ..... ' %_ ''_' "_:" :; '_''_:_" I _ ' " 'I' " _ " _'': " ''' ' ...... " " _' ' will disturb the:action ofthe'entire piston, rings;.......

... Removethe.,:bearings from the_rod and cap:: ' ,and. connecting ,rodassembly and:may.be the. , . , . .i:.. .... .,ldentify the bearings if they are to be.used.again; .cause of,excessive oiLconsumption,. ,

. ,. , _;;_,;,_;Cleantheconnectingrodsinsolv:ent; includingthe ;: ,:...:: insp,ect:the,cohnecting:,rods,f0rsigns', of frac-'

! ..... :....... : ;.. rodbore_and,theback of.the inserts.,Do not usea. ,. tures'ahd:th_ bearin"_bores for out Of round and....... "- _ "" , = ._' , : .-, ,- _ _",

............ '_,caustic'¢leanings°luti0n': Bl°w°ut:a!tpassages_. ,,,;. taper If;the..bore'exceedS:themax mum mitand/.... '. , .,with,compressedair. . .. _.'. '°'or;ifthe_,rodis':fra6tu._ed:;_'it'!shou.d;be_:replaced.', '' .. , . , .... ' ,

: • • . ' Inspection ' ." . , - , .: ' : :-,. _,'/,_,_::..:".::.Oncor_nectingi'6dsth'at,haVe'apistonpin bush-, ' ' • . , "";i":.',..:'-Theconnecting"rods and'.related.:._)_irts'should_-_.,:,_ing;check_the:_pistonpin;toconnecting':_r0dbushing .'

. _ .::.,_ ``_`:._`be:`_car_efu_y_inspected_;_a._fd._:checked46r_cdnf_r-:_._`:_._;_:c_earance_`:.:Rep_ace_the_c_r_necting_r_d_thebush-, .,• ,,.....:lng-lsso_wom_thablt;.cannot_be_,reamedor.honed:v-. : ';.... ?.-,.',_mand,e,to:speCifiCatrdns:!,,Vario_Js';fofmS_'of:engine!..... " ....... ;..... " '..... ".......

• , , , . • . ' . t : ' , • •

,, .,_-::",•,.....,,.. .._,_.,,.._;_:,,wear::,caused_by_these:::par.ts_can:_be_rea:dly,:, ,: ;for.,an -0versize:_pin:::.-:.:-/,.... /: ,.... :,,: :_. ,/-,.... :, _identified. ' ..... ;Check the ID'of the connecting rod 'piston pin

.... •" ,"A shin Surfaceon either in boss side of the ' ' bore Replace the connecting rod if the pin bore is

., ',"pistonusually indicates that a connectingrod is' : ,not w_thmspecff]cat_ons.Replace defectwe con-.: . ._'bent or:thepiston:pin hole is'not in proper:relation ,i-:, :necting::;:rod_nuts:,an.d_:b_)!S_i;:_"'i:_.;_,,i::!;..

...... ., ; tothe pistonskirt and ring.grooves. -... ,;,...,::.:. :,:,,._After_.the.connecting,.rods;ar.e:iassembledto the......• :' ' '- .:"_:-;:_:_"Abhormal:c0nnectir_gredbearing wearca:n_be_:_,:___piston,checkthe rods for.,,,bendor_twiston a.suit-' ,...

...... ,,_:_-:_::causedbyeither a bent connecting rod,.an im;.....:, ablealignment;ifixture._Followthe:,instructions of, ...... . ..":_- :t ;:-'::properlymachined'journal;ora' tapered Connect-:,': ':::theffixture,manufacturer,:'lf'°thebend,and/or:twist

..... ing .rod bore. ..... :_:.::::::`_::`_:._:_:_exceeds:specificati_ns,;!_the;r_d_:must:be:straight-enedor:replaced. ' _ ' ,

.... •:.._':PISTONS,-_'PINSAND.RINGS ' -: ..... ,: with rmicr0meters at,tl_e'centerline: of,the,• piston bore and at 90 degreesto the pin bore

. Cleaning axis. Checkthe ringsideclearancefollowingtheRemove depositsfrom the piston surfaces, procedure under Fitting Piston Rings in this

Cleangumorvarnishfromthepistonskid, piston section.

pinsandringswithsolvent.Do not use a caustic Replacepistonpins showingsignsof fracture,cleaning solution or a wire brush •to clean etching,orwear. Check the pistonpin fit in thepistons.Cleantheringgroovewitha ringgroove pistonand rod.Refer to Pistonsand Connectingcleaner.Makesure theoil ring•slots(orholes)areclean. RodsAssemblyin the pertinentengine section.

•_ Checkthe OD of the piston pin and the IDof the .:Inspection pin bore in the piston.Replace any piston pin or

Carefullyinspect the piston'sfor fractures at the piston that is not within specifications.

ring lands,skids and pin bosses, and for scuffed, Replace all rings. Check the end •gap and side• rough,or scoredskids. If the lower inner portion of clearance. It is good practiceto always install new

• _ the'ring grooves have high' steps, replace •the ringswhen overhauling an engine. Rings should,piston.The stepwill interferewith ringoperation not be transferred from one piston to anotherandcauseexcessiveringside clearance. ,,:, regardless of mileage.

Spongy,eroded areas near the edge of thepistontopareusuallycausedby:detonationorpre- ": • _ _ignition.A shinysurface on the thrustsurface ofthepiston,offsetfrom the centerlinebetweenthepistonpinholes,can becausedbya bentconnect-ingrod.Replacepistonsthatshowsignsofexces-sivewear,wavyringlandsorfractures,ordamagefrom detonation or pre-ignition. CLEANER /_t.\_\ ,J

Check the pistonto cylinder bore clearance by :_ ,measuring the piston and bore diameters. Refer to ..... _"the specificationsfor the proper clearance. Referto Cylinder Block Inspection for bore measure-mentprocedure.Measure the OD of the piston A9402-1A

Page 393: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•........,:_:_[;_BA$1C_ENGINE_.':,,:_,:';'; ..-, • ' • • 1-14__ " ' -_' ,1,14_:....•....... " ; "......"..... - ....,,.- •........... , ..... - ' , __;i;:"'.',_:,i__.:i_

CLEANING ,AND INSPECTION (Continued),

'_'MAIN_!AND CONNECTINGROD `'``..``.'•.`:i,: .......... (_YLINDER. BL0C_K ''_ " •

/ :,,BEARINGS_,.' ...... - "'

:;-;:cleaning:,::.,.'"." : .. ' • ' " " ".... " _,fter anycylinder bore repair operation,suchas-'; Clean the bearing inserts and caps thoroughly honingor degtazing,cleanthe bore(s)with soapor_;;in solvent, and dry them with compressed air. Do detergent and water. Then, thoroughly rinse the ' :_.

._:-..notscrape g_Jmorvarnish deposits from bear-• bore(s) with clean water to remove the soap or :",__- "";;.'.ing shells. _-_:, detergent, and wipe the bore(s) drywith a clean, '_.q..... _. lint-free cloth. Finally,wipethebore(s) witha clean ..'-. . cloth dipped in engine oil• Ifthese proceduresare " "" "j;_

_i' i'! _i__ not followed, rusting of the cylinder bore(s) may " ;;:

occurIf the engine is disassembled, thq[oughlyclean '- ... , ,"i BR,GHT_POUSHED) the block in solvent• Remove old:g_sketmaterial •

% : SECTIONS : • . ',"._ .... ,:

'_:-:__;..-_}:_ ""_"_ . .from allmachinedsurfaces•,Remov._allplpeplugs';i_: ,_...., i'_)_!!:i "'.._._:'. :,,FATIGUE,FAILURE ""';_.' , '.;" '.. "." 'IMPROPEWSE ,'_TING''_ _' :"' '" ' ."•that seal,oil.passages;thenclean:gi_t,all.thepasL!::; '... "

i_ IIII'II'_:':_" ;,._ sages•Blow out all passages, bolt _L;ioles, etc•, with

.,_;.. .,_:_ compressedair•

i_i:. binding and result in a false torque reading. Usea:. tap to true up threads and to remove any deposits. _.,_i.: ........

I SCRATCH E_ DIRT IMBEDDED OVERLAY

;,.-;+ i ,NTg.BEAR_NG MATERt.AL WtPEO OUT InspectionSCRATCHED BY DIRT LACK OF OIL

After the block has been thoroughlycleaned,.:."'_: .... checkitforcracks.Minutecracksnotvisibletothe , i;_

':ii_!i'-_i_i"iiI"...... i. ,".......... ,_;. naked eye may be detected by coating the sos-pected area with a mixture of 25% kerosene and .,

• _75%lightengine oil•-Wipethe part dry,andimme-• diatelyapplyacoatingof zincoxidedissolvedin _'_i

OVERLAYGONE RADIUSRIOE wood alcohol. If cracks are present, the coating •,,;_:FROMENTIRESURFACE will become discolored at the cracked area. Re-

TAPEREDJOURNAL ; RAO,USR,OE place the block if it is cracked.A2903-1A

Check all machinedgasket surfaces for burrs,Inspection nicks,scratches and scores. Removeminor ira-

• Inspect each bearing carefully. Bearings,that perfectionswithan oil stone.Check the cylinderhaveascored, chipped,orworn surface should be block for flatness of the Cylinderhead gasketsur-replaced. Typical examples of bearings that face following the procedure andS,specificationsshould be replaced and the causes are shown, recommended for the cyhnderhea_;'-ThecyhnderThe copper-lead bearing base may be visible block can be machined to bring the;,cylinderheadthrough the bearing overlay. This does not mean gasket surface within the flatness specifications,that the bearing is worn• It is not necessary to but not to exceed 0.254mm (0.010 inch) stockreplacethe bearing if the bearing clearance is ,;removal.fromtheoriginal gasket surface._," _ : ', •within recommended limits. Check the clear- ' ' Replaceallexpansion-typeplugsthatshowevi-•ance of bearingsthat appear to be satisfactory dence of leakage.with Plastigage.Fit new bearings followingtherecommendedproceduresas detai_edunder Mainand Connecting Rod Bearings.

Page 394: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' ....... ' ........ :' :;- i-• ' ...... i:,......._._...... ,' _,.1-15,_.:-,..... _,..•.":' , . . ,..... ._,':.:;_::BASIC•ENGINE,_ .... i_,;":_...... o. . ,. ,•., : _. ;. , .,, _ ,,,1-15"".:.:.' ,/' ,i

CLEANING AND INSPECTION (Continued)

';:'_.,' _:'_?lnspect'_the'cylinder,,,walls_,for:scoring,-',rough-.,,,,:_:'.... ... • -. " ;,! _i:_.`_':_ne_s_or_:_ther._._ign_fi_wear_Ghe_k_:the_cy_inder_`_:`_`_`.., ........

''..,,,.. ':,?.';,:i. ,_.::o._.,,.L..boreforlout.,0f:r0_ind,ahd.taper:,Measure,the0b0re................-- ... _,--CENTER_NE"OFENGINE=-_ A.. with an accuratebore gauge following the instruc-. AT•, tions of.the manufacturer_Measurethe.diameter. RfGHT" ANGLE

..... -.,: _ :,.;ofeachcylinderboreatthe top, middleandbottom.:..-...... -... - TO": .:'.:_.with the gaugeplaced;at right angles and parallel ..-. CENTER

.... :. " ._.:'._,to'thecenterlineof_.theengine:Use only,themea.................... ,,a LINEOF..... , _:.,:surementsobtained ,at:90degrees ,to the en- ENGINE

.,.',:,,.,-,ginecenterlinewhen::calculating thepiston to - PARALLEL., ' cylinder: bore•clearance. -_'_'_:_ '"TO

..... ..'; ',:Refinishcylinders.that are deeply scoredand/or ....... ::.:,,. _CENTER. - ,.,LINE.OF

.whenout-of-round.and/or_taper._exceedthewear _"• .ENGINElimits. :_"_: i:'.-;,i"='v :- "-" :'- " " : _;_ " "_i: '- " '_ ,,'r ",'_.:,..... 1."OUT_OF:ROUND-" DIFFERENCE_BETWEEN,

_.._ ""i':'"J',':::,lf:'the/c_/iinder,:waiis;:" l_av.e, minor.' isu rlface" --' " " " " ;"' .... " :2. A,ANDTAPER__DIFFERENCE:BETWEEN,THEIt.: . - "' .. ; ,

. ._ .... :,,_damage;.,buttheout-of-round and,taper,are within •'MEASU,EMENTATTOPO_" .:"'-J;. ,::,.limits,:itmay_bepossible.to.removesuchdamage: -. • CYLINDERBOREANDTHE.A

J.',_:.'.by,honing :the cylinder:walls and installing new .... MEASUREMENT.AT:BOTTOM,OF' :":'.:':'-':"J : ....._servicepistonringsprovidingthe pistonclearance - ....._--\CYLINDER:,',,,.................BORE , . ,..A 2905.A

•. J - _iswithin .specified limits.

_OIL PAN .'Inspection •

.: .... . '-'__'Cleaning . --. . ' .... .. :-•, ............ ._:- .: _':;"_Checkthe panfor_cracksTholes;damageddrain,:..: :....,_,,,_,,o_,,,,.,,_;,+_,,,_,_,_:,,_,,..,,,_ ,,,,,_.,_,_;,_;_;__:_::::-"plugthreads;and:a_loose'baffle::Cl_eckthegasket. . •

• ,....... _,.... _ ............. _,....... o........ _ .... ,u_ surface for.-oamagecaused byover.'torqueo.....bolts '............. :,/:::!of:the;pan:'Scrape'all,oldgasketmaterialfromthe '":_-_ .... : _ _ • " ":_':_!":_..... ;,..:.:gasketsurface..Wash•thepaninasolventanddry ........"Straighten the.surfaceas requiredtorestore origi-.

it thoroughly. Be sure all:foreignparticles are re-. nal flatness.moved from below the baffle plate. Replace the pan if repairs cannot be made.

Page 395: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

CLEANING AND]NSPECTION (Continued)

_OIL PUMP .....

...... _/ash all parts in a solvent and dry them thor-oughly with compressed air. Use a brush to clean

_:-- the insideof the pump housingand the pressure ,...... ,:.._relief valve chamber. Be sure all dirt and metal ' "_'

: particles are removed_ "

Inspection .,i_-,._. Refer tq_.thespecifications for clearances and.:i_/ wear limits. .

_" Check ..i_einsideof the pump housingand the ,.._;i." :; INNER TO OUTER ROTOR ', _,_P'_:_* _

," _,., outer race'and rotor for damage or excessive wear , , NOTE: TIP CLEARANCE_MUST_NOT_,_!__ , .' , " "_:"_';':_'i_'_ ;,'._-, _,'or,.scoring.."., " ' " "" ' " " - " " " ': "' " EXCeEO0.305mm (0.0'I21NC'I_)iWi'I'H:"" ".' '. "'-"!;;_';'_ " • • FEELER GAUGE INSERTED'12i,7mm : ', " . -, '

__" mating p_".,, Check the surface ofthe ump coverfor ' ' ' ._z.)MINIMUMANDROTORS.....'_:_' REMOVEO FROM PUMP HOUSING.',_, .wear. If,the cover mating surface:is,worn, scored_. ,s_se._c.

or grooved replace the cover,

Measure the outer race to housing clearance.

With th_!rotorassembly installed inthehousing, -..--.place a straight edge over the rotor assembly andthe hdusi_g. Measure the clearance (rotor end

,_ play)between the straight edge and the rotor and_:., outer race:

"r';_= The outer race, shaft and rotor are replace- _able only_as an assembly. _ . :i_i

"Check tl_edrive shaft tb'hd_sing bdaringclear-'_, ance by measuring the ODof the shaftandthe ID.

of the housing bearing, iilEi ,,_,__

Inspect the relief valve spring for a collapsed orworn condition. Check the relief valve spring ten-sion. If the spring tension is not within specifica-tions and/or the spring is worn or damaged, -replace the spring. _

.' Check the relief valve piston forscores •andfree

operation in the bore. ..÷,. .?_;:.:. ;•_q;,,,.

'_ : t' i

POSITIVE CLOSED-TYPE CRANKCASE _:_. ,,-'VENTILATION SYSTEM ":_

' Sl_akethe cap dry and install it. Do notdry withCleaning c'ompressedair as air pressuremay damage the ",

Do not attempt to clean the crankcase filterelement.ventilation regulator valve; perform the Clean the crankcase ventilation systemcon- 4",_,"Functional Check." nection(s)onthe carburetor spacer or intakeman- .-,

... The oil filler tube breather cap, located on the ifold by probing the inlet nipple with a flexible wirevalverockerarmcover,shouldbe cleanedat the or bottlebrush.

.. proper mileage interval. Remove the cap and Cleanthe hoseswith a low-volatility, petroleum- _.. •washit in a low-volatility, petroleum-base solvent., base solvent and dry with compressed air. i

,.,*-,, ;._,_, .... . '-_

Page 396: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

OVERHAUL

" _"_'"_::_"'/" "" -_:"_':_'::':"":'R_l_laceti_ 'h"ead_ifit_i_Oracki_d:Dbn0iDianer----

' r or grindrnore than 0.245mm (0;010 inch) from

... .... the cylinder, head.gasket, surface. Remove,all .;.!i" ' .,; :',,.-,:_burrs.or:scratches_with,an:oil,stone., -

, " REAMINGVALVE GUIDES

. , .-,;._. i" ' ,;._:lfit becomesnecessary.toreama.valveguide to. •..... :', ;:::.Hnstallavalve with,anoversizestem; a reaming kit

.......... ' ,'._.;.;.",is,available ,whichcontains ,thefollowing, reamer, :,., . '.,.:- "':_.'".,andpilotcombinations:a,0.003qnch OSreamer

• . ' : ;,,_.,.:with ;astandard_diameter.,pilot;_a:0,015,inch_OS

" ' ...., ,......; _:::i'_::',_..'.reamer_:with_;0_003-inch_OS:piloti,:and;ai0.030-::._',,'_._,;;,,;,':_,,i::;_',;:... ,.,;Jnch-Teamer!witl_:a'O':015-inc_;;OSi•_)i10t,:,,.?.._._',:'":;.. ...."

, ....... '... , ,.,=:., ,When going,_,fromastandard size,valve to an ,,' , : =':oversize,valve.°always,usethe reamer' in se-

..... - .-..-i: .,_quence..Alwaysreface:thevalveseat after the." ........: . .:_-.: '._.'_'-.:',.valve.guide,hasbeenTeamed,anduse aisuit-_."_m!.:_,".........'""_._:_'.,,._,able;scraper'to,break"thesharp :corner_(I : _."_,_'.,_i_

":.' _',.'the-top of the'valve'guide. ' " "- 'o. / _. ;_::_!!,!'

• "' _"REFACING VALVESEATS ': :

' _ ';.,L ,,'',_"Refacingthevalve,:seat'shouldbe.'cl6sel_,cE0r-"......:_::,'::.,,:::_dinatedwith.the;:refacingof:the valve,face::sothat=.,::.;.:,.:,._;,,;":,,,the'finishedseat and,'.valve.face:will,_,'' be:concentric.., ." .;, -

..,:... . ' ......,,": .;,:,and,,the._specified-interference:"fit:,will.be.main-_...., ..,......... ':,tained.:Thisis.importantso that the.valveand seat -_

will haveacompression-tightrfit. Be sure that therefacer grinding wheels are properly dressed..

Grind the valve seats of all engines to a true 45degreeangle.Removeonlyenoughstockto clean BREAKSHARPCORNER ; : A2910-1D

up pits,and groovesor to correctthe valve seat [!iii'i!iii__iiii!ii-i!!_

runout.Afterthe seat hasbeen refaced, use a seat TOREMOVESTOCKFROM- TOREMOVESTOCKFROMTOPOFSEAT, BOTTOMOFSEAT,.,widthscale or a.machinist scale to.measure,the use_o°_,_EL USE60°WREELseat width.

If the valve:seaLwidth exceedsfhe ;maximum ..

_ limit, removeenoughStockffromthe topedge and/ ...... .:.

specifications,or bottomedge of,the'seat toreduce the'width_to _ [i "

• On the valve.seats of all engines, use a60 _ It::I::.:_'i,.V.:ALVESEATWIDTm_Hi::.i_

degeeanglegrinding wheel to removestockfrom _l . i;:,:i?iii:_ :E'

-:_ i!;_ -

the bottom,ofthe seats(raisethe seats) andusea ;: .30 degree angle wheel to removestock from the [_ !!_ii:_i_:;;top of the seats (lower the seats). Li_i::i_:?:;ii;_::;::il_ AZ_9,-_C

Thefinished.valveseat shouldcontact the ap-. I_" 3Ji. SEATWIDTHSCALEproximate center ofthe valveface. It isgood prac- L_tice to determinewhere the valve seat contacts I" ........:;:..:::i:._

the face. To do this, coat the seat with Prussian ..i::::"blueandset thevalvein place.Rotatethevalve i_1with light pressure. If the blue is transferred to thecenter of the valve face, the contact is satisfactory.

.... If theblueis transferredto thetopedgeof ther"_' "_'valve-'face,,,lower the-valve"seat,.If, the blue is

transferred to the bottom of the valve seat, raise

the valve seat. . .. AzRo_._s

Page 397: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

_:._J1;18_:._,, :_,,. ...... ,,. : _:_',-,_ ,._:,,_.:, ;_..".;_'._BASIC_ENGINE;_:J_'_:_!;:_,_...... 1-18_'_:....... _' !., . . .. ,.. - . ,_._,,_;

OVERHAUL(Continued) ......., , q

.,VALVES ......_. .". ,_:, ' "' '" - ' ' DO NOTREMOVE MORE' _ • ' "" "

' . , • ,, ' , ,.... 0;254mm,(0.010.1NCH)i: _ .; ,/_, "" i. :.,. _,,_._/i;,Minor,pits,,,grooves/etc_:,:may_bei,removed_._Dis=,:.'..,:/,./..:;' FROM'THE'END ...... "_' "_ ': " ."

:-• card valves that are severely damaged, or if theface runout cannot be correctedby refinishingorif .,•

_i_, stemclearance exceeds specifications. _'_":: FOR BENT STEM " _':,':_ " ;"_

,,_,;..... Discard_anywornor,damagedvalye trainparts._-'i, ")_ ETERREFACING.VALVES EOR DIMENSIONS -

,,:'.' _i_i REFER TO SPECIFICATIONS :.. .:._

: ',, Theval_e refacingoperationshouldbeclosely./'- coordinatedwith the valve seat refacing opera- .-......'.!-i tions so that the finished angles of the valve face ,_..:... . .-,.,;i_and the ,va_lveseat will be to specificationsand ,, ;_;,_........ . .,. .:

)royde."a_'compr.essed-tght-'fit,Be,:sure .that_.th,e.,_.--..:.: ,. _;. .. . .... ..,,:_,grind ng_'whees:,are/proper y'dressed '_. ..... " ' ' - ...... , ...,',;_-

_-_. ffthe.valve, face runout is.excessive: and/or to ., VALVE.- ' FACE ANGLE'

::. ' remove"pjts.andgrooves,"reface the valves'toa'

true 44 degree angle. Remove only enoughstock•;ii;:I_ to correcti_therunout or to clean up the pits and _/=_ inch_ M_NIMUM

- 0.794rnm rills LINE PARALLEL

....'i.:, grooves. I':[_theedge of thevalve head is lessthan W_THVALVEHEAD ,:,

" " 0.794mm!(1/32 inch) thick after grinding, replace ";•, theval_e as thevalve will run too hot inthe engine. } A._=._E

" The interference fit of the valve and seatshould not be lapped out.

_-;, Removeall grooves or score marks from the SELECT FITTING VALVES; endofthe,valvestem,andchamferitasneces- "_

:' sary. Do nOtremove morethan.0.254mm (0.010 If the valvestem to valve guideclearance ex-...., inch) from the end of the vaivestem: ceedsthe wear limit, reamthe valveguidefor thenext.oversize valvestem. Valves with oversize,

" If the valve and/or valve seat has been refaced; stemdiameters of 0.003, 0.015and0.030 inchare _

it will be necessary to check the clearance be- available for service.Always reface the valve .....tweenthe rockerarmpadandthe valvestemwith seat after the valve guide has been reamed.the valve train assemblyinstalledin the engine. Refer to Reaming Valve Guides.

CAMSHAFT REPAIR_,.

Remove lightscuffs, scoresor nicksfrom the ' _'_/: • . .,camshaft machined surfaces with a smooth oil ,:/_:._stone.

", , . , ' ' ,

Page 398: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'.': ..i .......i++:'+._+1.;191+'-+.++,+++".'+'+ ,:• •.+",+ ..... ". ...... , ,"_+':"++'<'++J' ++" ' '+ +'+ i"++ II"+ '+" "_........... " " ' ' ' ' ...... + II " " ............. + II '" +I +r+" ++

• ........ OVERHAUL(Continued) ......

,:, " ,_,_.!_Y'CRANKSHAFT-!+;"-.,+._+_", _:.,+ ....+: . ++.,,,. FI1TI'INGMAIN:OR CONNECT, ING _,ROD+'_,+,+'_, + +'I+_:_'_+"+.... " , " ;.... "+ . ...... . +--. BEARINGS_WITH;PEASTIGAGEi.:_% +.......• + _ * r. ++ ':'_' , +' " " " " ''+ + +i_ ' ," _ , " • :+ _ +_, V" + + t+ . ' + ++ _',

'"'+ .... I " '"Dres+. minor.+scoiesw+tl__+an oil..st0ne.+.fftlqe"• "1' journals are:severly_marred or,exceed the wear .: •1.._CleanCrankshaft journals:.:inspect journals

" ' ' • " _ I . limit;they should be refinished to size for the next,. " .-. -,arid thrust faces: (thrustbea_'ing) for nicks+.i . - +.. ' ..I +_,._undet-sizebearing(' '.... ,_' - .+,++-...... ., .....,_+.. ,+, ,,.':::_._.+._bUrrs0r:beari'ngpickup that'w0uldcause+pre-'

I ...... .... ,::;_,:mature+bearing,wear,._.When_replacing,-stan ....

+' +' " " I:+'_I:IY+"'REEINISHING;JOURNALS+' ' + '++'_ '"_:L ' +",-i+:'+dard+,ibearlings+"withiilnewi+ibearings,it +,is

': ,,., +'._/Refinishthe+,journals+,to:givethe.the+proper • " =:_;:..:r'+_i_rg0Od_pra(_ticei"to',,'rfit'lthe+;bearing,tomini-• -',,.::.:._,,+mum,_speCif+ied_clearance.+:lf+,the,desired' : +,:_.•+.++r:+".+_+_,clearance!with;:thenext+undersizebearing.:'lf+the.. ....... •,+:!::.clea.ran_e.c'a_nnbtbe_obtainedwitha standard

.... "++journal,will' not'clean up-,to,.maxim,um',undersize. +' .... +::+bearing,try,one_half,,of+a:0.001..or0.002+inch, ' .++.., ,,,bearingavailable; replace the crankshaft.+-:..+'. +._:.:...../?!"udde'_,i_,e!b'e,_Pinglin"i_,'OhlbinatiS+nwith a stan-

' ++"++.... : '_ :.+?_+,,;,,!+;Always:reproduce,the:,same-:journai:.+shouldet.._+.....

++,,,.,+:+o.,,._+,>+..... ' ,+_-_radms+that+ex_sted++or.!gmally:,;,,Too+small"a,+rad_us._.., .+:" ," +:::2.+.+::,_.lf_+fittinga.,main+,bearingiUposition,a;+:jackiun_ ..."+will+result:infatigue+fail0reof the crankshaft,'T0_)_ I'-+';-:+der counterweight adjoining bea_;ing

? .+.',+ ._;+.-'_:,,largea_radiuswill+result,in'+bearing:+failuredue to _ • _,:?::-whichisbeing checked.,Do not,placejack, radius rideof-thebearing. " .., under fr0nt:_post of, crankshaft. Support

...... ;'"+ .+":+After refinishing_the+journalsi-:.cl_amfer(the'oil''_ •...... _+i_,,..++_:_i!cfahkSha_with,jacR_soiitsi_W+e!ght_willnot com-' .:,.-i_+._;preS_+_lastiga_ge_i:_.r_d_iprovide;ianerroneous.- ,.• +_...+._+"+' .'_._holes;.,thenpolish, the journal with a No.ii320"g'rit.+,,_+-

• ,.++.;.,.:_,. '+++polishingclothand_,_engine.oil:'Crocuscloth may+:!;,, , . _"i+_readin(__..... :+<:`+_":.... + ';' "++:" +_' • ....

• .... , ....._+ +.:,i_also,beused as a polishing.agent.• .... . ,,.... ,+;_:.3,_+,+,_lace++a_Piece+0fi!p+!astigage;_on.beadng.:sur-+ +:+_.:_+.::+:faCeacross.:full,width,of,bearir_gcaplandabout

. +.,,1/4+inch+off_center.._ _+.,.. ......

.... ,...... _.+", :+:.., , .+_,: +-.__+-._.+"+_::+-:+'_,4_::: lnstall,cap,and_torque_bolts+to,specif cations._+-.+++:Do+inot turn_cr_n'kShaft_wl_ileii'Plastigageis in .=

.... ._ 5:" 'Rem0v+ cap. :+Usidg:Plastigage scaie,+checkwidth of Plastigage at widest point+toget min-

CHECK WIDTHOF mum clearance. Check at narrowest point toPLACEPlastigageFULL get maximum clearance. Differen(_ebetweenWIDTH OF JOURNAL

ABOUT6.35mm(1/4INCH) readings is taper of journals.OFF CENTER

..6. If,clearanceexceeds specified limits, try 0.001or 0.002 inch undersize bearings in combina-

........ tion with the standard bearings. Bearing clear-+ance must be within specified limits. If 0.002undersize main bearings are used on morethan one journal, .be sure they are all installedin cylinder block sideof bearing. If standardand 0.002 inch undersize bearings do not

.... bring clearance within desired limits, 'refinishMEASURING crankshaft journal, then install undersize• INSTALLING : 0.0015" Plastigage

Plastigage CLEARANCE bearings.

,_,+_.A 7, 'After bearing has been fitted, remove thePlastigage and apply light coat of engine oil to

• , journal and bearings. Install bearing cap.Torque cap bolts to specifications.'

8. Repeat procedure for remaining bearings thatrequire replacement.

Page 399: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

;..... : ",. ,._:,. _:._._,,:.:_-:J:'_BASIC_ENGINE_:_?":"'_. . .' , . " 1;20!.. ' , _

OVERHAUL(Continued)

. . . ,FiTTING':PISTONRINGS_,,'.,:_,,s ,, , , :,, " .... . ',,,: .:_;:.PISTONS_iPINS_'_AND?.RINGSI,!,_.,i," !_r,, _:_.'. ,! _ ....

,_i,FITTING_PISTONs._:_/!::.:I._,.,-:-, ,, • ,- ,.. ,..... . i :., 1. Selecttheproper ringset forthesizecylinder,_, bore.

' Pistons_are available for service in standard.._, sizes and_itheoversizes shown in the parts book. 2. Positionthe ring inthe cylinder bore in whichit _._:_.! ..-_,;_-

_.:.: ..Thestandardsize pistonsare colo_;coded,redor is going to be used._ blue, or have .003 O.S. stamped on the dome. 3. Push the ring down into the bore area where

Referto the Specificationsfor standard sizepiston normal ring wear is not encountered. .., . ._

_;. dimensions. 4. Usethe head of a piston to position the ring in ' "_._:i,' Measu_ the cylinder bore and select the piston the bore so that the ring is square with the . '_,_, to assure_itheproper clearance. When the bore cylinder wall. Use caution to avoid damagei_-,, diameter_[sinthe lowerone-thirdof the specified to the ring or cylinder bore.. /; "

_._;;::_{ _".,:....range a red ptston.shouldbe:used..;,Whenthe bore, • 5; _ ..... reth..... betweenthe'e_,_sbfthe"rin"" _ ";_:/_l_ '""..,diameter,is" n,thernidd e_one,thirda_'bue_pston_......., "..:,L _, ..... '__. __ ,, ,,..... E L2E .._,-.._._.: , ;"

.:_.'_'_':".'1 .!:'S ..... , ............... ' " Wltll t:l.:/g_l_P (,,l_U_t3. I/ LII_ "lllly-i,,l_Jl:5 It3_._.Ul ,',, "

:_. : 'l _, snouzaDeusea wnen me oore ozame_er.tsin me " -reater than th^ _'"e^ifie "_limit;- t- anoth^rJ%:'_:,1_i,-_!i. upper.one-third,-the;O.OO30.S..;pistonshould.be.:.. ':. r n- set.- ':_:"_;"'I .__ used. _:_. Y . .

__?: "_""1 -_ . 6. Checkthe nngs_declearance of the compres-_::.;_._.,........ [. Measur_e,the p_ston....d ameter to ensure,that the S,v"n,,-ngo....._, th °- feeler _'a'=_''einserted b"=-";._,:.-_-.,,,, specmeo(clearance_sobzamed It may Deneces- --- "_"...... d i'^ ow^r I^n" T,h -a -^:_,._•_ .._-. sary penoo_caHyto use anomer p_ston [re(] or ....I .... should s de free y around the entire r ng c r-I.. _.. blue) tha_ _s e_ther shghtly larger or smaller to cumference without bindin- An" wear that_i,_.._.• • _ ..... _.... _. Yachieve the specified clearance

I occurswillforma stepattheinnerportionof] ., If none_canbe fitted, refinish the cylinder to the lowerland. If the lower lands have high

i_ J ,,'. provide the proper clearance for the piston, steps, the piston should be replaced.- .=, _;, When a piston has been fitted, mark it for as- ' _',,_' / sembly inthe cylinder towhich it was fitted. If, , _ the taper, out-of-round and piston'to cylinder

_ boreclearance conditions of the cylinder bore"are within specified limits, new piston ringswill give satisfactory service. If new rings areto be installed in a used cylinder that has notbeen refinished, remove the cylinder wallglaze(refer to Cylinder Block, Refinishing Cyl-inder Walls). Besure to clean the cylinder borethoroughly.

1. Calculate the size to be used by ,takingacylinderbore check. Followthe proceduresoutlinedunderCleaningand Inspection.

2, Select the propersize pistonto providethedesired clearance(refertothe specifications).,

- Measure the piston diameter in line with the ;_.,, ,;., - ,.centerline of the piston pinand at 90° to the A_OZ-_epistonpin axis.

3. MakesurethepistonancIcylinderblockareatroomtemperature(70 degrees F.). After anyrefinishing operation allow the cylinderbore to cool, and make sure the piston andboreare clean and dry before the pistonfitis checked.

Page 400: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

".......:_"_; ': "':_'1'__.'i'-. ,.....: .._:,_ .,.-:, . ,_.,. _ .....' . .. . .1,21_'T '' _ :

•OVERHAUL,(Continued) .....

" |

I= ._' If the.padat the valve end of.the rocker arm has

'-- " ' ' " a-grooved.radius;'.replace:the.'rockerarm. Do not' ' ' ' " ,_.:attempt to,true _this,sUrface_bygrinding. :','"_,.

_.,PUSH'RODS ........... "'-':.............: .......,:"'""

: :.", ' :",.:';_':.:- :".:..FITTINGPISTON?PINS';J i/;,: ..-i.'.);:'". ' :, ,i. ::;.",}'_,_- :',_.)'-Followingtheprocedures Under,Push Rod in,spection,,check_the push"rods for straightness.

.. ,...,.- " :,,-.:_Thepiston:pinsare selectedto.give,tne- --: " -- correct'.," _- If the.runout,exceeds the maximum limit at any: , .,, , ,..,., fit,in thepiston, pin bore and bushing in the con-- ,:_o6int;,discardthe,_od,!_Do,nOtattemptto.straight"

,, /: necting rod." Pistons-are only ,supplied in-"SerVice:"..._' ,..en p. - .-' : ;' :: :::,kitscomplete_with :the piston pin, ,to ensure.the" usJi_t_ ,J"°::i:""_:_":"!!'_:_:_:"_':'_:"_"_i_"_'d

n _

........ correct'_fit::T_he piston ' pins should':_not.be '_ :- .......... " _'_.

........ ,:nterchan=e,.z ,,_ . .....

i,:.. i • ::_, :, . :i: .':",i•. :,,:., •.•....-..:._: :;P

Page 401: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•.OVERHAUL (Continued) ......

,::_CYLINDER.BLOCK, _.......' . • _..,_...REPAIRINGSAND.HOLES_ORPOROUS.:,_:','::: :... . :...._, ' _' , _. _ .... ;',ENGINE •CASTINGS;_'._._/;_....• ":_;_ . .

- i

." Porosity or sand hole(s) Which will cause oil iHoning,:isrecommendedfor refinishing cylinder seepage or leakage can occur with modern cast-

_:...:- walls only_when the walls have minor scuffs or ing processes. A complete inspection of engine _/:. _'._:-;: scratches_:or for fitting pistonsto the specified -. _,;:

-_:"!'i_ clearance"_Thegrade of honeto be used isdeter- and transmission should be made. If the leak is -• ._ mined by,_itheamount of metal to be removed, attributed to the porous condition of the cylinder

_..! . _ Follow the!instructionsof the hone manufacturer, block or sand hole(s), repairs can be made with - . .•i,metallicplastic (Part No. C6AZ-19554-A).,Donot ,"_._'_ If coarse _iones are used to start ihe honingoper- repair cracks with this material. Repairs with " .

._-_ i._: ation, le_ye enough material so that all hone thismetallicplastic mustbeconfinedto thosecast -. _..!, marks ca_. be removed with the finishing hone iron engine component surfaceswhere the inner -

',,_ :. which isi_used to obtain the Proper piston wallsurfaceisnot exposed toengineceelantpres- i"'clearance_! ..sureor.oilpressure',_:for'example:_..:_:!_!i_ii__, . ..... '

.: . .i::4Cylinderwalls_.that_are'severely;marred"and/or.:,, " 1: "Cylinder block surfaces:extendin_"along:the':, . :_:! ._c; worn beyond the-specified limits should be re- . lengthof the block, upward from theoil pan rail......_:_;_ " finished.,Before•any.cylinder is.refinished, all,. " to the cylinder•water jacket butnot including

_,'_';,', !,,. main bering caps must be in place andtight- machinedareas._Z: _;i_ ened to _theproper torque so that the crank-" " :i shaft beating bm;eswill not become distorted 2. Lower rear face of the cylinderblock.

from the:refinishing operation. " ' 3. Intake manifold casting.

,!. Refihish only the cylinder or cylinders that re- 4. Cylinder front cover on engines using castquire it. All pistons are the same weight, both iron material.

: standard,a.ndoversize; therefore, various sizes of- pistons can be used without upsetting engine 5. Cylinder head, along the rocker arm cover

.... balance. " gasket surface. ,,_

" ....... Refinish the cylinder with themost_,wearofirstto The following procedures should be used to_•. . determine the maximum oversize. If the cylinder repair porous areas or sand holes in cast iron:

will not clean up when refinished for the maximum a. Clean the surface to be repairedby gdnd-oversizepiston recommended, replace the block, ing or rotary filing to a clean bright metal :',_,

Refinish the cylinder to within approximately surface. Chamfer or undercut the hole or0.0015 inch of the required oversize diameter, porosity to a greater depth thanthe restofThiswill allow enough stock for the final step of the cleaned surface. Solid metal must sur-

•honing so that the correct surface finish and pat- round the hole. Openings larger than 1/4 _tern are obtained, inch shouldnot be repairedusingmetallic

'_, plastic.Openings in excess of 1/4inch canForthe proper use of the refinishing equipment, be drilled, tapped andpluggedlusingcom-

follow the instructions of the manufacturer. Only " men tools. Clean the repair._'_,'areathor-experienced personnel should be allowed to per- oughly. Metallic plastic will not'stick to aform this work. dirty or oily surface. --.

, Use a motor-driven, spring pressure-type hone b. Mix the metallic plastic baseand hardener..at a speed of 300-500 rpm. Hones of grit sizes _;',,,i" as.directed.on-,the.container,. Stir;thor-,; :: .'_180-220 will normally providethe desired bore ,';' oughly until uniform.

:surface finish of 15/32 RMS. When honing thecylinder bores, use a lubricant mixture of equal c. Apply the repair mixture with a suitableparts of kerosene andSAE No. 20 motor oil. Oper- clean tool (putty knife, wood spoon, etc.)ate the hone in such a way as to produce a cross: forcing the epoxy intothe hole or porosity. _'i_

_..:_hatchfinish on the cylinder bore. The cross-hatch d. Allow the repair mixture to'harden. Thispattern should be at an angle of approximately 30 can be accomplished by two methods:degrees to the cylinder bore. After the final opera- heat cure with a 250 degree lamp placedtion in either of the two refinishing methodsde- 10inches from the repaired surface, or air -:_

. scribed and prior to checking the piston fit, dry for 10-12hours at temperaturesabove"thoroughly clean and oil the cylinder walls. Mark 50 degrees F.

the pistons to correspond to the cylinders inwhich .....,theyare to be installed. When the refinishing of all e. Sand or grind the repaired area to blend ......

_' -'_cylinders that require it has been completed and with the general contour of the surround-all pistons are fitted, thoroughly clean the entire ing surface.

• block and oil the cylinder walls, f. Paint the surface to match the rest of theblock.

Page 402: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

ADJUSTMENTS

•...... _:..'",._ALVE..CLEARANCE_.,-,_,_",.... ,. :.

' ' : :"'" ' "" : A'1':52mm (0:060;_in(:h)'"shorter'Push"r0d0'ra " STEP_I"-'SETsTRoKENO:1'PISTON'ONADJUSTNO. IT:D:C:;AT_END'OF'COMPRESSIONINTAKEAND EXHAUST "£' ' "STEP 4 - ADJUST NO. 6 INTAKE AND EXHAUST •. '1:52mm(0.060inch)longer.pushrodare available

• .. " • ' 'forse.rvicetoprovideameansofcompensatingfor ..,

. , _...:. :; :_ _::._:_:_:_dimensional_changes:-in_th'e,;valve:mech&nis !• :.-:_".:_:,.: ;.'_i':.-::Referto,theMasterPartsl:.ist0Fthe'spec ficat bns:.:.

.. .--.:-_'for.the'pertinent.colorcode.. __. , ....:-,:..:-,-:.,.';:.i'-q

": : ."_"":--:"_Va:lv:e_..'stem' to valve,, rockers.arm.Clearance':.:'';::__,:._:J........... _ "::.;.:'should.beWithinspecifications:with th'e hydraulic.::":":_:::.".__.

:..:.:_.._::ta:ppet_completely,collapsed:.:Repeated,,Jalve:re_:__'-,,:-:':'_-_• : ; ' ,,.-.' _._conditioningoperat0ns (valve,and/or-.val_/e'seat'. .-..,. ;_:.._.?...._,::._,,_:.i'efacing).wi iideCfease_,the_c,le_.raJic]e_t_)..,the:_p_)idt._;!";--:_,.,;_,,;-_..::-.,-..:;...;.._.,i.':',_'_that:.if:Jt.is:not;CompenSated_for,;,tb_hydradlic)yalve,is".. !:.-, .'

....... .. .: -', !_.::.i.,:tappet,wJil;collapse::_and:_:cease,iiio:functioni.,_and_...........;,,_:.,:-;,couldprevent .the.valve -seat.face from properly

?' ,'..--: seatingon'the valve seat..Valve.will.be"heldopen., -

•. " "_ -"..::•:..:,-fT.hepositivestopr0cker:arm:bolt:eliminatesthe. ,.:-. :i ;..:necessity,of adjusting,the-valve:clearance. How- ,-.._.::_.::,._:..;_:,,.,...::,::,_:_:,:,.,;..:........ _:.,,:.:..:

....... >..__,.:every,:to obtain'thespecified.valve"clearance, it is ._,.... :importantthat all'valve components be. in a ser-

" ",.. STEP_2:_.'ADJUST, NO. 5 ,-;'_ " " "_:'"'._":"c'_'STEP3-ADJUSTNO. 3.. . "-." _ ._.._,_'.viceable_:condition,and installed and tightenedto IN,T,AKE,ANOIEXHAUST"'" .*IN'FAKE'ANDEXHAUST.

..... :specifications. :STU;S.:-_'D_0ST'NO:_.... : L.."..'"_":STEP_-'/,DJUSTNO.4'..INTAKE'AND EXHAUST -=. :':_ ;" _:,'_" .;.,L:_.:INTAKE AND EXHAUST

. ..... _::. :-:_odeterminewhethera:shorteroralongerpush.. ._- .... , _...... ,.. :-: .._........ ..,., :_ .- . ..• . _.--, rod.isnecessary;_make,thefollowing:check. " , .,........ :: " :" " ' - ' Az_:_,*

;"'. •1.: _.lnstall,.an:auxiliarystarter.,switch..Crank the ...... ._:,,. - _:,...-;_-.:._..._..:_.,.,._,.:__--_:-_,.,_,._ :,._:._-,,_,-...:...-.,.__._:;:--._._-engine.with the Ignition switch Off. • :

2. Make two chalk marks,on:the crankshaftdamper.Space the marksapproximately120degreesapart so that, withthe timingmark,the damperis dividedintothree equal parts TOOL-T70P-6513-A

(120 degrees is one-third of the distance _|aroundthe dampercircumference).

3. With No. 1 piston on TDC at the end of the . := --compression..Stroke:..:tighten;.the:rocker armboltsof the.No,.1.intake,and,exhaust.valvesto.

specificati0ns' " - " " "...... ":" 1 ""

Then slowly supply pressure to bleed downthe hydraulic, tappet until the plunger is com-pletely bottomed using Tool T70P-6513-A orequivalent.

Hold the tappet in this position and check

the available'clearance between the rocker ___;_._...__ /

armand thevalve stemtip.witha feeler gauge.. ,FEELER

If the clearance•is:lessthan specifications,' GAUGEinstall a shorter push rod.

A22.32-1E

If the clearance is greaterthan specifica-tions, install a longer push rod.

4. Repeatthisprocedureforthe remainingsetofvalves,turningthe crankshaftwithan auxiliary. ....

starterswitch, one-third turn at a time, in the .......• directionof rotation,while'adjustingthe valves • _ .

in the firing order sequence, 1-5-3-6-2-4.

Page 403: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

I II "

REMOVAL AND INSTALLATION

• i vENTILATION _......................"".............I ' _ .,,Installation..:.... :,. :,. ,..i"ti rli,.:_:;Re_ovali:;::L,..:/,,::,,,', LI_,,.,,,i .:,__i"/, ,':.: :...,_ :,:_"1'-!i nsta :the;,inet,';tube:in'!.theiintake:manif0d_,,,;_,:;i.:;:. ,, . , ,, .-,i._"1'_ 1. 'Remove'tlle air cleaner. 2. Installthe hose on the inlet tube in the intake

Ii " 2. Graspthe crankcase ventilation regulator manifold. Install the regulator valve in theI ' ' valve and pull upwards to remove it from the hose. .. , ,,

I rocker arm cover. 3. Insert the regulator valve into the rocker armi.• 3. RemoVe the regulator valve from the vent

cover mounting grommet.i

I'-, hoseand remove the vent hose from the net_, tube imthe intake manifold. Connect the air inlet hose to the crankcase ,.

I filter cap and carburetor air cleaner. '_"I,.: 4. Rem0,ge the inlet tube from the intake • 4. Install the air cleaner. Operatethe engineand

I : manifoid, check for leaks.J,:,,,.!,,..5.. Remo_ethe,air inlet hose from thecrankcase ..... !;.ii!,::_:_:!',,

'i';_/_!:i_:_.::• ::::"_filter_cap_'and:icarburet°r_air:cleaner"_::'_':i::i_''''_':':I' ......."" ....."i' " • , • ':>,C,',_,,,'....

'i_ _,._

%' VALVE ROCKER ARM COVER AND• ROCKERARM

:"_ Removal ATTACHINGBOLT1. Disconnect the inlet air hose at the crankcase

', filter cap. Remove the air cleaner. FULCRUM R__M _, 2. Disconnectthethrottlerodfrom the carburetor

throttlle lever. Remove the throttle cable ROCKERA "( _':;

bracket from the cylinder head and position _-"_,_L_\ _z--_ ';'• the cable and bracket assembly_.out'ofthe

_.... way. ,,

3. Remove the crankcase ventilation regulator FULCRUM'GUI _,._tvalve from the valve rocker arm cover, if soequipped. Remove the cover bolts and re-move the valve rocker arm cover. . THREADED PEDESTAL

4, Remove•,the valve rocker arm.•bolt,-fulcrum . L'_--_ ._,.....seat and rocker arm.

Inspect the rocker.arm cover bolts fordefective', ._:, .seals under the bolt heads and replace as;. .:%_:'-;-:_.'A,_TO._Anecessary. . .

The valve rocker arm assembly is shown.

Installation ,'; ....

1. ApplyLubriplateto the top of the valvestern 4,' Installthe cover on the cylinderhead. Makeandat the push rod guide in the cylinderhead. sure the gasket seats evenly all around the

2. Apply Lubriplate to the rocker arm fulcrum' head. Partially tighten the cover bolts in se-seat and the fulcrum seat socket in the rocker quence, starting at the middle bolts. Thenarm. Install the valve rocker arm, fulcrum seat torque the bolts to specifications in the sameandbolt. sequence.

3. Clean the valve rocker arm cover and the 5. Install the crankcase ventilation regulatorcylinder head gasket surface. Apply oil-re- valve in the rocker arm cover, if so equipped.sistant sealer to one side of a new cover gas- Install the throttle cable bracket on the cylin-ket. Lay the cemented side of the gasket in der head and connect the cable to theplace in the cover. Be sure the gasket is carburetor.seated properly around the extruded bolt:. , 6. Connect the•inlet air hose to the crankcaseholes, filtercap.

Page 404: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• , . . .

•.REMOVAL• AND INSTALLATION (Continued)

" ...,'.'.', i. ,.:".i:i.i;" :<""'MANIFOLDS'!I""_:::" " " --. that:the gaskets .,have.not "become•dis-., 'i..; .,"/. -. " " " " " : :_ _. :':i: . .' Iodged:dnstall:°the:attaching:_washers,",:;.,':'.

.... '.... ,: '._-_,,r ...........:RemovaP. - -boltsoandnuts..Torquetheboltsand nutsto., _,.1:..:Remove,theaircleaner:Disconnectthechoke :, :specificationsdn,_thesequence'.shown.

.......... cableatthe carburetor.Disconnectthe throt-•... ., .. _ , .,:L-/__,tler0d from,the:carburetorthrottle lever,TM ........ "- ,'"_"_-_;:. ,;,,- " ..... . " .

• " " . .:.,:,_2:r_<Disconnect`thefuel,inlet line and thedistribu-•- - . .... :,";tor_vacuum.line.ffromthe carburetor. : ._,,,,, :,, : . .,.......... ,STUD

. - ' , .., .'.

_,!, _ ' '.:..,:,:: _- '._ 3.;;',_Bemove'theboltsand nuts'attachingtheman_-,:., _,.",'.'( ,, :_,,:• , .. i '._:.:.,.,._,ifoldsto_the:cylinder,head. ILift:.the.manifold

:.....:.. t >- ::_'_;aSsembiesfromtheengine._Removeanddis-

_. ; .....card-thegaskets................. !_;,_:_4::.,:-,_To_.separate_the:mani,folds,_remove:the_nuts..,/_,!._-:,,,

: ,,., . .:_,,,:;-.,,;:_...,:_;.,_,/,_,:jbining,:the;.intak'e_and;_!exhaust:manifoldsT_,_',.-::_,..._:_. •

t "" " " P ' ' +r --. Installation

, ...... ' .:-. . .... If• the 'exhaust "gas' control valve requires.re- -" . .. ::._ :: _ _:placement,'::follow.theprocedures.in,the pertinent ..... .- ....,-d

':"._........1.:":Clean themating surfaceS'of.the=cylinder ........ " ." •- ..:head,and :manifolds. ..... FRONT "

..... 2._..:lf._one;of.,the:manifoldsis.tobe replaced, re- _..._,:.:.,-,, -...,:_ . .,•., . . _ _...... ,. ; -. .', ....-,_::_:_move_.the,_tube;ffittings:,:from.;the._discarded

::,, ., .-_-manifoldsandinstall.theminthe newmanifo d - . -. -'o-., _'. :. : , " • ": .. , .• : _: -" • " _- ;' " ........ -" "h n w":J_:'__:_'_lftheiinzaKeand_exh_'ust_mariif°lds:weresepa- :, • • ' .' i;manifold: •.... .- , . •....... : : .:..-::.mzeo_z_gn[em.me,nu[s.]on ng::mem.../

.............. :, ,., ".':.'3._J' Iftheintakeand exhaustmanif01dsI_avebeen.•..... "6";:__c°nnect;'thb"_:crankcase;:veht_h°s'e_t°_the__iiY"_:-"• ' - separated,- coat-the mating.surfaces .lightly - take manifold inlet tube and position thehose

with graphite-grease and_place.the exhaust- clamp. .manifold over the studs on the intake mani- 7. Connect the fuel inlet line and the distributorfold. install the lockwashers andnuts.Tighten vacuum line to the carburetor.

them finger tight. 8. Connect the throttle rod to,the carburetor4. install a new intake manifold gasket. -• throttle lever. Connect the choke cable to the

5. Coat.the mating surfaces lightly with graphite carburetor.grease. Place, the manifold, assemblies in 9. install the air cleaner. Adjust the engine idleposition against the cylinder_head._,Make!sure speed and idle fuel mixture.

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. REMOVAL AND INSTALLATION(Continued),,,

' •:::CYLINDERHEAD " :'

. ,. ,..:,:_Removai:,_:, _.,,.......,, , . _, ,,:, . , ...... ,,• :"' ' i0W oc ,oN.Fo, .... ,-- •_ .... Ir'the'cylinderhead iSto be repla'ced;f01 the ...... "

" ' :i procedures under Cylinder Head Disassembly

ii andAssembly.Transfer all valves,springs, seals, , 'j_-i' ' :':i_ spark plug's,etc., to the new cylinder head. Clean . ........:,.:,, ,,:._.,,_and inspeEtall parts, reface the valyes andcheck' _ valveguideclearancesbeforeassemblingthe:.,_ , , used parts to the new cylinder system. - .:,:),• ) ,,%

,,,, ' 1. Drain;_thecooling system. ..

'(%1.': :'. 2. Re e the air cleaner. -

...... 3. Rem6_'ethe crankcase ventilation regulator•' " _ i: ' , vave :'f. ,so,equ pped ,.,from.the,,rocker,_arm. , _,. • ,".. ., ,:v:',,,._,c,_-,-::' :_'!'i'::"' "'!_c0ver.:Disc6nnect,the:vent:hdse;:at'theintake:':T'';"::< ',__',_ ......... " . ,,,_'_",_,' :_:,"" ! 'i<:_ . •manifold inlet tube. _1_ ',

_'_" _'" FRONT

_::,.'",.... _"_ 4. ,Disconnect.and remove',the'.carburetor-,fuel,",..... ' A3187-1B

•,":':: inlet line and the distributor vacuum line.

_.,,:.. ":_:, 5. Disco_hect the choke cable at the carburetor.% ,--

":.. and Positionthe chokecable and housing out Installation -:_::_"' '":"_ of the_way..:,.... , _. 1. Cleanthe cylinderheadand cylinderblock:'- 6. Disconnectthe throttle rodfrom the carburetor gasket surfaces, Clean the exhaust pipe,....' .- throttl_ lever,',-," ., ,,,_, 2. If the cylinder head was removed for a cylin-_,::,,, _- 7. Disconnect the radiator upper hose at the der head gasket replacement, check the flat-_!.,_. _: coolar_toutlet elbow, ness of the head and block gasket surfaces.

_"," ". 8. Remoye the coil bracl_e,t,,,attachir)gi_bolt,and 3. Positionthegasket over the dowel pins on the,!::,_i: ._, positi0i_the coil out Ofthew,_y. ': cylinder block.

-: 9. Removethe valve rocker arm cover. Loosen 4. Install liftingeyes on the cylinderhead in the ,.':,the rocker arm bolts so that the rocker arms location shown and use a floor crane and _""can be rotated to one side. lifting sling to lift the cylinder head over the

10. Remove the valve push rods in sequence and cylinder block. Lower it carefully until it is•prop,identify them so that they can be installed in erly positioned on the block and dowel pins.,

'their original position. Removethe hoist and lifting eyes. '

11. Disconnect the spark plug wires at the spark 5. Coat the threads, of the,cylinder head boltsplugs. ", with engine oil. Install the bolts. ,..

12. Remove the cylinder head bolts. Install the 61 The cylinder head bolts aie tightened in:threecylinder head lifting eyes in the locations progressive steps. Follow the-.isequenceshown. Position a floor crane and attach the shown. Torque the bolts to specifications.hoist and lifting sling to the lifting eyes. Lift the 7..Apply PolyethyleneGrease DOAZ,19584-Aor , ' .cylinder head and intake and exhaust mani- ,,;_equivalentto.,bothends of the push"rods"."ln-":." _ : .......... _folds assembly off the engine. Do not pry stall the push rods in their original bores, posi- .

_, between the head and block asthe gasket tioning the lower end of the rods in the vanesurfaces may become damaged, tappetsockets.

."i

Page 406: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

REMOVALAND INSTALLATION (Continued), j

--_ '8_,,,_Apply!Polyethylene:GreaSe_DOAZ49584_-Aor,_,_:_"_,. _ VE"SPRING;(RETAINER-_AND. STEM,::, _,:

"__!_.i_,!;.i.,,,ii_'_.'ii:_i!!i_i!i_:,_.;_;_:equivalent_to_the':rocker,_armffu,,- . : .. . ,. ,. . ,. . c'rum_seaband_:..:... . ..._,....... ._,,:'.,SEAI%.,,_,:_:..,:. :_: .. " .. ..". " ...._,_ .....:_" "the"'fulcrum_seat"s0cket°ih":the_rsCker"arm;.:................ '

-.. .... :Positionlthe.rockerarms and tightenthe bolts.. .:.,.. ,.Broken.val,e...springs 'or deiectivevaJvestem

•._: ::'.. _. _9.._:Cleanthe valve:rocker_armcover.Coarone.., . " '. seals.and, retainei's,mayfbe.replacedwithout re-' '. :.-_..: _,:-:-I',':W:";.,:_.:_sid(_:of:a",new.:,valVe_r6cke_:arm_cover'.gasket'i-,.:,_ ;.,Jmovingi_ecy inder,:head:providing;damageto,the" i: ",. :.' ?-/-_,-:::._.-:with.oil,resiStant:sea,ler.':l:ay;the :cemented;: _ r`" _'_::" "._val_e!_0rvaive/seat,:ihas.,'_0t"°Ccu_e_d;iI-,':': "'"'., -'

' ".. "....,. :_ic:'side:ofthegasket.inplacel, inthe cover,...Posi- , ;'Remi_v_l::i.',:_".:'. ':__ii:,''_'" _'i"._ :'::.:i_,i_.- ._-:...-..:._.'._ " -.i-:"":tion-theIcover;.!making.,sure:that_,thegasket'.'i, ,:...!....:....Ll,,:::i_,:.,!seatseVenlV:aroundltheicyiinder_head...install;,_..

"_::': _'_":'.""1 "_',-'_:thecover,bolts'and.torquejr_,sequence.(sta_-_.:_: .:_2..:_Didconnect'the_th_ottle!r_od,,from_thecarburetor

!., ._i". _.-'i:_,"1"::-..__:..ing,in,the .center).tOspecificat!ons.. 'o-. .. :..: :: :_:,_,_thfoft_._:}e_e_!ioD}s-Coon'e_ct_t_,_;Clb"okec&bleat

: :" " ....:I_:17'_:'Connect: the isp'ark.:plug,;wires_ito',the'-spark- " " "__ithe_;carburetor,,:,,_;-_,!._.._._.,.,,.;,.i.;_i:.._,_:i.;:_.,:-,:,...,,_":,_.,_,_ ::.,_-_:plugs.._........, : ";' :...... _:: ...... ' _._:,-'.' .:..,,,;i_,... .;'3._' Remove_"the'_crankcase'._._entilatiQn.',regu[ator,:,

_1 ct_thec ev _hse_ '" ' '_ ,.., .,..valve:from,the.valve,;r.ocker.armcover and"!::._",:".,'....._-"_.!;;4 :/Conne rankcas " ent' o to.the'inlet-:'- . " "" " ..... .. o::/:: :..._;:::..tube,in,,the.intake,manifold..Install.the;crank-,.. .. . ' ' .:,.removethe valve'rocker,arm cover..Remove:

........... case-ventilationregulator valve .in thewalve..... ' _. the applic.able.sparkplug..,• .i ,, :, ::rocker arm ,cover.. _ . '..... ._ _. " ,.. ".,..,.......,:..:: .:,.4: ._,_G_aak_the_engine,.until_!the_;aPpl.icablepiston is

...........",_- _L:.12::PosJtJon,tl_effueli:inletline and:theedis{ributor:: _ "" '_-S:";:_:!_O0:_'_DG_ilafter_the;_compr_e_sio_str°ke"._"' ,- ,": -, c,_,, .........._"_" ,vacuum'line.omthe,engine._Connectthedis,.."...... •.... _'5_.%lh ;' ' ug'hole

, ,:,.:" : :-_tributorvacuumline,to_thedistributorandcar- .. ..... iand.:;bbnne_tthe:air_line. :' ....•" " .:;::::_buretor.:Connectlhe:carbureto_ fueLinlet line ,, ...,_........ ........

•:,.;,.:_,to._!the'carburetor:and:fuel-pump. •....... ;---._-::_..... ;6,_,:Bemo_e_the;app!icable.valye_rocker,arm,bolt,..... "_ • -;:, .:: :,.!_,fdlcrum-'s_at;_iv_zlve;.r_ocker.:ai'_._andpush rod.

' _;_':_i"_-'..._:13::;,,Connect-the"throttle:_rodto.the,carburetor.., ...:.-_;,;,J,_'./;_iPoSitiSn:the_c0mpressdrtooliasshown.Com-"_:'.,,_::.:.:,'.:ithrottle:lever...Connectthe_.chot_e.cabie.to,the_,,,i :_.;.,:,,;_?.;:,,,;,':_preSs_!.tlSie_qal_/e_;_,lsrihg:;:,a_nd_r,em'0ve !the:re- :_:

.....'-__;:",o '" ca_'bUretSr_" ' .'" . " . _ . . .' _ ." " ,. _ _ L:.":::taide[_:lo'_kS;:spi:ing_reiainer,iand_yalVe_spring:: I:-. " "..,, _.:14._.Connect.4he,:radiator_upper_.hose _,to._.the-..:.-....

• coolant:outlet'housing. VALVESPRING""

15. Fill and bleed the cooling system... COMPRESSORTOOLT70P-6049-A _

16. Operate the engine until temperatures havestabilized. Adjust the engine idle speed andidle fuel mixture. Check for fuel, oil andcoolant leaks.

17. Install the air cleaner.

A3245-1C

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1i

...REMOVAL AND INSTALLATION (Continued) .

i.,i.,,.9.,.:_:lf.thei;ondition,of.,the:valveprovedsatisfacto..._f.:...!.,:./"'r" .... . .,_ ,,,,hold::the_valv.e::in_the,closed!positiomand.,,;:_,."::':..: _.:,,.;,: . • : '

iiiairi;pressure'_wi'thin_the'cylinder;,......... ._..,__ ",......'.... _..i :_,:_,_

...... Installation

:_ :; 1. Oil the valve stem with heavy engine oil and .:!_!: : " install a new valvestem seal. Place the spring ' '- "i

in positionover thevalve. Be sure the closed

,;:_::i! coil end is next to the cylinder head. Install - _ :i_._the valve spring retainer. Compress the valve _';_:i

_: spring and install the valve spring retainerlocks. Remove the compressor tool.

2. Apply PolyethyleneGrease DOAZ,--19584-Aor _ ,_

.. equivalent to both endsof the pd_'_rod.,install '!!!::::'_.:._,.ii.!_...I thepush!rod. Apply,Eubriplate_t_)ilih_e-tip,of_.th_e:.;ii.,-._., :-; '" ;; ,:i",ii:/_:_

,'A_RL,NE :'_' ' ' _;valve.stem.:. ' " ' %.'.:_.'. '

_sg._c• 3: Apply Polyethylene:GreaseDOAZ:19584-/_or" .,:_,.. equivalent to the fulcrum seat and socket.

If air pi_essurefails to hold the valve in the Install the valve rocker arm, fulcrum seat andclosed position during thi s operation, it can be bolt.

presumed that the valve is not seating or is 4. Turn off the air and remove the air line and•/ dama ed If this condition occurs, removetheg_ " adapter,installthe sparkplugandconnectthe

cylinder :head for further inspection, spark plug wire.

7. If air'pressure has forced the piston to the 5. Clean the valve rocker arm cover. Coat one" bottom of the cylinder, any removal of air_.. pressure will allow the valve to fall intothe side of a new gasket with oil-resistant sealer.

cylinder. A rubber band, tape or string Positionthe gasket on the rockerarm cover; ._,..... wrapped around the endof, thevalvestem be sure the cemented side is towards the

•:.'. will prevent this condition and will still al-. cover. Install the cover, making sure that the,.. low enough travel, to check the valve for. gasketseats evenly aroundthecylinder head. • ._,._

binds. Installthe coverboltsandtorquethemin se- ,._quence (starting in the center) to spec-

8. Inspectthevalvestemfordamage.Rotatethe ifications.valveandcheckthevalve stemtip foreccen-tricmovementduringrotation.Movethevalve 6. Connect the throttle rod to the carburetorup and down through normal travel in the throttlelever.Connectthechoke cableto the •

-valveguideand checkthe stem for binds.If carburetor.the valve has been damaged, it will benec- 7. Install the crankcase ventilation regulator .. '

•essary to remove the cylinder head for're- !,. valveinthevalverockerarm covei_lnstallthePairs as outlined on page 1-26. ' .... _ air cleaner. __f_:: '

Page 408: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, •.... _. ..... ., . i,29_:_..... ... ...... ' ,. -.- ,'--_'-_BASIC ENGINE:_:",": ' ' • _" ....

• REMOVAL AND INSTALLATION(Continued)

" _.•. ::":"':.:!:i!:"VAIr'VE::;T,APPE_;-,:".•;I'/•:•..,, " " .... •'

..... _' _ ": :" :'_ ". " Removal: '. :r,., ..- - , • ' ":--:'_.'_ :-.-: .... 7 _. :' MAGNETIC VALVE TAPPET REMOVER" .'

" ' .1•- ..Remove the.aircleaner. Remove the crank-..::-.,_., ,.;::,-caseventilation:regulator.valve:from.tl_e

• . • . • ' , ._:i;_!,.,,:!::.;....:rocker,arm "cover.:.'_.":'.,._;.':,' _;,_",."_-,

._:_:_:.,2...,,.Dtsconnect,tbe:chokecablet...:::_• -'..,;...... _',,",.:'-:..;:.Disc.onne'ct;,.the,,;:th,ro_ttle.,:cabl:e:_!

.::'..:.:-:::: :_"_.!:;.,._:_._,_:3:;;_:Remove?the_'coil'_:bli_.' ,-" .-: .....:L-.I .....::,..,_:_-:::po'sitior_,:tl_e:coiloutof.the

Ii.:.:::,;::_..:,;::-_:.i;,_l_..:;:.5:::_::_Disc0nuect_tlie_spark_._plug

i:li:::::::: "::_:::plugs.and':the.,:secondary"_higl_'tension_wire.......:"

.'...fill ! i":_:_#°mthe:c°il":Rem°vethe_distribut°r:capand:'"""::spark plugwire.assembly., "'

,. " .,6.:_.Remove:,the:valvepush rod coveK _. .... ::_i:::ii_.,: _::'.:._A_,i:iB'

• _::<,_7.;.:o_Loosenthe'rockerarm bolt(s) untilthe rocker _ :':::"_:::_"::::_"_'__ ...._'" _ -"_........:....... I " " " :

• / ::::_.arm(s) .,can:be disengaged'-fromthe..push : .. , ....., _....... . ,- .... .

I

_•.'- ,-..rod(s).Remove.the_pushrod(s). Remove the " _-

: . ,. .:: .r:_:valve:.tappet(s):with.the,tool shown; If more " ''_' ::::"_:...... " : " " "• ' ._::_::._;_:_than:_one:push:._rod_and_,valve:tapPet:_iS":re-:" : _:4::_'_Tighteln_:tl_'e"_a:lye__ro¢_k.e_r/_a'rmi:!b°lts.to.. :.:

:: . __: ,:.::..:.:::..:.moved,d0fit_insequence:andplace._theparts": :-.:-...:'i:'specification,,:, ! :,, _..... _- _-,..........".:_ ' ' ,.... .__;._:_`;_.:iin_:a_r;ack_s_they_can.:'be_:insta_ed._:in".their_`:`_`_:i_5_:_:`G_at!_:_ne_side_f`._:new_g.as_et_Vith_i_re-_.;:./i :':'_-_..:'.i

" ":.'::-:.',::.::._odginal_lo(_ations:.:,..._.... . , ,:,., -, _:"_ _.,._,.*..-:_,_-;:._,,:-_::sistant.:isealer,_and;;p0sition_the_gaskets._ce-_;.. - ", . : ":;i_.. - ....... :.... _."_...... menteds_detoward:_he;cover:..-Install:thepush'. +"::"1_ ';_:"'_:_

.. :_lnstallation . rod cover and the:'rocker arm cover. Torque :_1. :Clean.theTocker:arm_cover,push•rodcover, . the cover screws •in.sequence to specifica- _',_

cylinder head and block gasket surfaces, tions. Install the crankcase regulator valve in _<_'

2. Apply Polyethylene Grease DOAZ-19584-Aor the rocker arm cover. "_equivalent to the cam lobe contact surface of 6, Position the coil on the cylinder head andthe valve tappet(s). Coat the rest of the valve install the attaching bolt.lifter(s) with engine oil. Install the valve tap-pets with the tool shown. : 7. Install the distributor cap and spark plug wire

assembly. Connect the spark plug wires and.3. ,ApplyPolyethylene_Grease_DOAZ-i9584_Aor _ , • coil.secondary high..tensionwire. ..

r equivalent:td:b'oth:i!ehds:_0f:the_push-i;0d(s); 8/'Connect the throttle cable to.the carburetor.Install the..push,rod(s):in;sequence:Engage ,: . Connect the choke:cable to the carburetor.the rockerarm(s)with push rod(s) and tighten"the rocker armbolt(s) sufficiently to hold the 9. :Install the air cleaner• Start the engine andpush rod(s) in place. Be sure each push rod adjust the carburetor idle speed and fuel

:, -_..,is properly seated in the valve lifter socket.• mixture.I

WATER PUMP

Removal

1. Drain the coolingsystem. Loosenthe alter- 3. Disconnectthe radiator lower hose at thenatoradjustingarmboltandremovethealter- water pump.

natordrive belt. 4. Removetheboltsattachingthewater pumpto2. Removethe fan and pulley, the block. Removethe pumpand gasket.

Page 409: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• +....BASIC_'_ +._..... . . ,':,

•REMOVAL AND INSTALLATION (Continued),.,

_:_" ; !,.-Installation . '"" _+2. Posifibn a new,gasket,.coated;on,+bothsides:, +.-,i!,+, , ,i ..... . ......... i , , ' 'i+, ,'' .withsealer/,on:tbe"waterpump: _+.,. +."_+ +" _!

'?:;ii_,:_+_=,;,;:,',,".:,:_._::",;Bef6re,awaterpump:,ism_installed+_check+it:for+_+:_,._:_;'; _;'..,,:°,.i::'., " ..... ., .... "- :,'. ' . .. _,..... :,ii," +, /,i ;i :i_;i ':.' clamage,ffit_is damaged and requires repair, re-'...... L_. mstaHmerpump'ooayonmeDiocK: installme ....

pump attaching bolts, coated with sealer and::,, place it. torque the bolts to specifications. ,

,_.+ 1. Ifa new water pump is to be installed, remove. 4. Connect the radiator lower hose. Install the

1 i!:, •, ,the fittingsfrom the old pump.and_installthem pulley and fan. Install the alternator belt andon the new pump. Clean all gasket material adjust the belt tension. Fill and bleed thecool-

....' I fromthe mountingsurfaces of thewater pump ingsystem.Operate theengine andcheck for _"iiii_,!, i:"' and _linder. block, leaks. _'._

_,_:,_+_CYLINDER, FRONT,COVERi:;,_,_:i."' . '.. ; ,. _,, , ,,, . .... :i_::; ' ..Removal '

:, : 1., Drain,thecoolingsystem.2. Removethe radiator.

(;:_;+,3• Remove the alternator adjusting arm bolt,

_+ Ioose_'the drive belt and swing the'adjustingj++,,,,• arm _t of the way. Remove the fan and drive_', btJlts:_

_'_' 4. Removethe screw and washer fromthe end '.:_ "/'ooi- T6 IP '6019 -B

!F of thelicrankshaft and remove the damper. _'_

5• Remo_/ethe front oil pan and front cover at- is completelyseated. Apply RTVsiliconesea-• tachir;igscrews., er D6AZ-19562-A or B or equivalent to the._" CAUTION" Prevent fc)reig'n_'rnateriaLfrom en- block/panjunction.

:;_' tering the crankcase during service•work •or NOTE:When applying RTV sealantalways • _,thecrankcase oil will have to be changed, use the bead size specified and,join the- "_6. Removethe cylinderfrontcoverand discard components within 15 minutes of applica-

thegasket. It is a goodpracticetOreplacethe tion. After this amount of time the sealantcrankshaftoilsealwhenthecylinderfrontcov- begins to "set-up" and its sealing effec-er is removed• tiveness may be reduced.

,+

Installation 7. Positionthe froni cover assemblyover theend of the crankshaftand against the cylinder ,,

1. Coat a new seal,with grease and.install the block. Start the cover and' pan •attachingseal. Drive the seal in until it is fully seated in screws. Slide the cover ahgnment tool overthe recess.After installation, check to be sure the crank stub and into the sea.'i_boreof thethe seal is properly positioned in the cover and cover. Installalternator adjusting"arm,tightenthe spring ,is properly positioned in the seal. all attachingoil pan and front;cover screws.

_.2. Cut the old front oil pan seal flush at the cylin- _i-_::I',NO,TE:'Tighten the: oil_I_an,screws,first'-,, : . + _, ' ",:........ der block/pan junction. Remove the old seal , (compress pan seal) to obtain propercov-

...... material, er alignment.

,3. Clean all gasket surfaces -- front cover, 8. Lubricatethecrankstub,damperhubI.D. andblock,and oilpan. the seal rubbing surface with Polyethylene ,;_:+

4. +Cutand fit the newpan seal flushto the cylin- Grease DOAZ-19584-Aor equivalent.Alignder block/panjunction.(Oldseal maybehelp- thedamperkeywaywiththe keyonthecrank-ful as a pattern.) shaft and installthe damper.

...i:5. Coat the gasket surfaces ofthe block and - 9. Install the washer and capscrew. Tighten to :_cover with B5A-19554-A oil resistant sealer, specification.

' _ Position a new front cover gasket on the. 10. Install the pulley(s), drive belt(s), spacer (if +-._ block, used) and fan. Adjust all drivebelt tensions to

•_6.+ Align the pan seal locating tabs with the pan specification." holes, pull the seal tabs through Until the seal 11. Install the shroud, radiator, and hoses.

Page 410: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' .. ....',REMOVALAND/INSTALLATION (Continued)':......

, .. .' :,"" _". ' ,2_.,'F.III,and_'rbleed_,the'_coohng_:system:..,Use::the:, 13:: Operate"theengine:at_fast,_idle':ahd:checkfor:..-_,.,_,,,........_-.._.,specified_antlfreeze, mlx..,..... If.._foretgn.;,mater.lal_.... - •-, .'coolant_and:_0il,_leakS..,_.',:.... . "

. . . . has'not.enteredthecrankcase.duringtheser-- , vice work, it is not'necessary to change, the

engine oil.

_:.: .- :_ ;:::FRONTOiLSEAL:! _'. ..... :-_-_"_" FRONT"COVER

Removal .".... . ":: :-- ,..-.' _E'AUF_E_CACER'

..... :;": ......l:'_._Remove .the bolts.attaching,.th_'fan::shroud_tO' _....... ..the_,radiator_:;._ . ..:...._,.,_.o,.-:._. ::,:...::,_.::_

" _. ._:.r,.,.,_2,1:,_:_Re(noVe_:the:_fa.b,_and_:spacer_boits!:,from_.the:_...,.:_'. • _:', .water pump "shaft. .Remove:.the: fan, spacer

_, ':.and .shroud. " , _:_:

..... , ,._ . _,...3..._Loosen.the alternator;,.power_steering,.Ther- ._• . : , : _: :, :, :-;_:-,.:,_.::mactor_and:air:i_b0nditioner_drive..belts; !if. so ' _:?"

..... •c:., :"'equipped.!:Remove:the drive =belts. ,:,i._ ,.: ::.,., • -:-:,:......

- ;:, .,:_-.:-..-..:_.,::_;';_:4:,_:_:Remove:_thecrankshaft:pulley:.: ...... "-: :_.,"", :-.:;:.;_:-_tion_dar_per:,,.Remove_._tl :lin

,. .............,_._...sc:.ew,_and.._washe_...,Install,,._tbe_,ppll_• ; •"... ::_;;,-_-'_;_',_:_.,:_cra.nkshaft_,vlbFaton•_dam_

. . -,.: , ,,::vibration.damper. _ -:- . . ...._.,::_.,

"_ i ;_5:.,:_.:P:lace:'..the_front..:seal-_r.emovlng,tool_(T or :.".- _ ...... : . . , • , ,

. . ._ '.'.' , _'T70P:6B070-B) -.onto.,'the"front.cover, plate ..:".::2:'::PJace_the:installatioh_-screw;"Wasl_er, and 'net' ::::"' - " .' ..", over the front'seal as shown:_Tighten thetwo

' through bolts:to-force the seal puller.under.the. , •.onto "the end ofthe crankshaft. Thread theseal flange, screw into the crankshaft. .Tighten the nut

against the washer and installation•sleeve to6. Alternately tighten the four puller bolts a half force the seal into the front cover plate. Re-

turn at a time as shown to pull the oil seal from move the installation tool from the crankshaft.the front cover.

3. Apply Polyethylene Grease DOAZ-19584-Aor_-'-_'J L equivalent to the oil seal rubbing surface of

the vibration damper inner hub to prevent

' "" ..... .'. ii" "..... damageto the seal. Apply a white lead and oil

_1 _"; " _., ' ..... mixturet°thefr°nt°fthecrankshaftf°rdamp"

:.. ,::/'. er installation.• 4. Line up the crankshaft vibration damper key-

way with the key on the crankshaft. Install thevibration damper•on the crankshaft. •Install the

_°_C°_v_R pulley.' TOOLNO. cap screw and washer. Install-the crankshaft

T_O_-_B070-B

A5765-1B

5. Instatl the alternator, power.steering pump,Installation Thermactor and air conditioner belts; if so

equipped.1. Coat a new front cover plate oil seal with

Polyethylene Grease DOAZ-19584-A orequivalent and place it onto the front oil seal 6. Position the fan shroud over the water pumpalignment and installation sleeve as shown, pulley. Install the fan and spacer. Install thePlace the sleeve and seal onto the end of the fan shroud attaching screws:

........ _.....,ocrankshaft.and push it toward.the engine until ..,the seal starts .into the front cover. 7. Adjust the drive belts to specification,

Page 411: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,_ ,_;:;1-32:_:'•, .... . ....... : ,.-,_;,, ::'_, .:_:_..:,,;_BASIC:_:ENGINE%_,;_,_.:u,.:r.• ' ,- 1,32.'11., " , : '•": ' ._. *: ,,. .... . .. , .. ....... . "L_:' :11"4

. ..REMOVAL .AND,INSTALLATION(Continued)i:, •

.... I _'CAMSHAFT,. .. , , ... ....... . -.,,.,.. 11.,.Remove.the-capscrewand,.washer.,fiOm'the_.i:':'. .'

• "'l"., " ,'Thecamshaft.and.related parts are shown. _ _om,,,,,, m= ,_=r_,,_ '._i;' I '! '_ i_"' "_" ' _''" ..... " _'_'"1"_'"

i_'/' I :' i i_; 13. Remove the cylinderfront cover followingthe q_ u_

.'::- 1 .: i. "i;',,FRO,T .NTE_M.EDJATEREAR procedure given in this section• ' .:_'_I 6EAR,"G ....... 6EAR,.SPACER :, 6262 " 6262 62626265 '_ . ' • */X. -'*_L':'' _. 14. Checkthe camshaft endplay, the timing gear

: _ ":;'.i_/ Z . "_1_, ._,, backlash and the timing gear runout. , : ....' s:

.>_tiir,...\_!r RUS,'PLE. / '. ' ' /,\. '.721;.... i'i"', - i_ .... _ • ' ". 6269, : . " , , ' . ,' /. ' . ',. ' "" ' " " " '

!.... \. '"/'._ • ." . ' "f .... i. .PLUG:'\' \ . . 'CAMS.AFT 6266.,',".CAMSHAFTSCREW 6 50

_.: : . GEAR . 20346-S,, ' 6256 A2830-1B

' Removal

1. Drain:thecoolingsystemand the crankcase.

:;, 2. Remo:vethe air cleaner. Remove the crank- ;...... case_/enti ation regulator valve from the rock-

er ar m cover.

ii • 3. Disco_nect,_.,, the throttle rod from the carburetor..... rthrottle lever. Disconnect,4hechoke.,cableat

....._ ,the c,4rburetor..Disconnectthe throttle atthe.carburetor and position out of the way. 15. Turn the crankshaft to align the timing marks

4. Remove the radiator, as shown. _"

5. Loosen the alternator adjusting arm bolt and 16. Remove the camshaft thrust plate screws.Removethe camshaft. Avoid damagingtheremovethe drivebelt. camshaft lobes during removal. Press the _'

6. ,,Disconnect the spark plugwires at thespark ' camshaftout of the gear in an arbor press.plugs anddisconnectthesecondary,highten- Removethe key, thrustplate andspacer.,SiGnwire at the ignitioncoil Remove;.thedis-,.tributor cap and spark plug wires assembly, i.:,/_:_,_

7. Disconnect the fuel outlet lines at the fuel CAMSHAFTTHF TPLATESCREWpump. Remove the fuel pump mounting boltsand position the fuel pump out of:the way.

8. Disconnectthe vacuum line at the distributor .iL ._ ._:' .".,":' .and the primary wire at the coil. Remove the

distributor.

' 9. Remove the valve rocker arm cover. Loosen• the rocker arm bolts, move the rocker armsto

.one side and remove the push rods in se-quence. Place the push rods in a rack so theycan be installed in their original locations.

10. Remove the valve push rod cover; then re-- ,:•;- movethevane lifters insequence. Placethe

valve lifters in a tray or rack to facilitate in-,_ stallation in the same sequence inwhich they • ".....,:.;. were removed. CAMSHAFTGEAR A2631-1E

Page 412: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i ,. ,_"::..":, :, ,.1_33..... " " '" _" BASIC:ENGINE ';:T:..... ' 1-33;; ,.,_.'.- . . ....... '.:_. ., .......... ::_:, _.,._-,

-.,,.,:,,REMOVAL.AND::.INSTALLATION-.:(Continued) .........

i' :' . .', -, _ " - "r.- '" ........ CAMSHAFT'GEAR:REPLACING ADAPTER"

"" o" _"_;_ ". _SJO_ " ".": .. " "

-.- . - ...

" -, : _", ::-- :i -" "

A2829-1D

,..-.'.:Installatlon _..

_'_If thecamshaft,endplay,.timing gear.backlash . .,:'.i -,,:and/or:timing-gear:runout .were,.excessive,-make

; ,"_i__._::,::_::.__-:,__,.':,;-._-,,:,_the:mecessa_y_!cor.r.ections_bPCfore_Linstalling:the__._:._::._:8,_:Clean_the_v:al,ve::push_od:_co.ver,_:ar3d:'rcylinder,, ....... : .:..,.:.::.camshaft, . - ..... '::.............. block,-.gasket,,surfaces_:__,AppIyi_6il,r,esist ant

....... •, _ , - ....•. ,_-sealer:to_one;s de:of_:anew.gasket.'and.place;". . ]'_c'::ui_zne:camsna:n-_oearing'journa s'ana;a:ppy ............ the_ asket'on tl_ _'' ' "_ '- .... ' :-;'-

..::::........_.'" • " .' " . . ' ........ :._'":..... ..g .... e pusnroo::cover,'wm me"':.....-:_._Polyethyle'ne_Gre'ase"DOAZ-:19584-A.'_or....."......?-."_,_ .-,, _.,:_-:": .,._-":-'.,."_:,.'.',-: ,'" ..... --:....... . ;: .... ,.. .... " .. ...... ,,':. ::_c::.:...ce enzeo_soe;.nex_',-,_0_;:me_coyer..:_,mSzall:z0e._..:._,...... equva ent to al zne_oDes , ,,: .,-::.:.,,. , . :_ :. : . • . . . .,.-., :o:Co_}e'l;_:_:n_,!!t_r__l'_(_':t_,?:i_it_i;i"_:::,_e'_i:e'_'-_O_..........

2.' Install'the:camshaft andthrust plate.. -specifications.

3. Torque the. thrust plate attaching screws to 9. Apply Polyethylene Grease DOAZ-19584-Aorspecifications• equivalent to the valve pad on the rocker

4. Positionthe camshaft gear on the camshaft, arms. Oil the valve stems with heavy engineoil. Align the valve rocker arms with the valvesAlign the timing marks on the timing gears as

.shown• Install the camshaft.gear with the tool and push rods. Tighten the rocker arm bolts.shown• Be.sure the gear and spacer are tight. 10. Clean thevalve rockerarm cover and cylinderagainst the shoulder on the .camshaft. head gasket surface. Apply oil-resistant seal-

er to one side of a new gasketand install the.. 5. Crank,the.engine,until .the.timing:marks_are_,; , gasket on the cover (sealer side against cov-

aligned. Do;not!:turn :the:crankshaft :again. ' er). Install the COverand torque the screws inuntil the.distributor iS_installed;" 'sequence to specifications.

6. :..Cleanthe_cylinder.front Cover_and cylinder 11. Install the distributor following the procedure• .:, ....... :" i ._•" _ blockgasket;surfaces..Install a new oil seal in ": in Part 2, Ignition:System..Install distributor

•: thecylinder front cover: Clean the crankshaftdamper and inspect it,, following .the-pro- with rotor pointing at number one. terminal

cedures0n page 1-11.Install the cylinder front position in cap, and armature and stat0r as-cover and damper, following • the applicable sembly poles aligned. Install hold-downprocedure under Cylinder Front. Cover clamp.Installation. ;. 12• Cleanthefuel pumpandcylinder block gasket

surfaces. Install the fuel pump with a new7. Lubricate the valve lifters with heavy engine gasket. Torque the mounting bolts to specifi-oil and install the lifters in the same bores from"

cations. Connect the fuel outlet line to the fuelwhich they were removed: Apply Polyethyl-ene Grease DOAZ-19584-A or equivalent to pump.both ends of the push rods and install the push 13. Install the distributor cap and spark plug wiresrods in the same sequence that they were as anassembly.Connect the spark plugwires

................. removed::Besurethe pushTodswere seated ...... i :_to°theplugs-and"the secondaryhightension -in the valve lifter sockets, wire to the coil.

Page 413: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" .REMOVAL ,AND_INSTALLATION (.Continued),_

':.1 _ . 14::Install the,lcrankcase_ventilation::regulator,,_.._'16..:.Installtheradiator::Connecttheradiat0r,upper,:":::,: _'"._'..I ...... :,,,:;_.;valve.in;the.valverOcke_arm:cover,.:;lnstall,.,the,!i:..;,.,'.i,; "i,.,hose,to ',the:thermostat;housing!,:cover:.,rCon-_i:i:,;i._:"::,,•i_'i,:!'_,;.:_:11..:;':_'!i.;i.ll!, /``_:_._`;:;_i_`_th.r_tt_e_r_dcab_e_h_jsii_g_br_ac_et!_n!.thei_cy_ih_;`!_::_`_`.he_t._the1_wer`h_se.t_thewater pomp, .... - '"• i ,, " ' der head Connect the throttle rod to the car- . ......... '

"' ' " h _ install me air cleaner "I .,;,_ buret:or throttle lever. Connect the coke " ' -

I ,:... cable!_andthe hand throttle cable.i_. 18. Fill the cooling system. _I,.i::_;'_, 15. Instai_i_thewater pump pulley, cooling fan and 19. Start the engine and check foroil, coolant and :' " "I i_' drive! belt. Adjust the beit te'nsion to fuel leaks•Adjust the ignition timing. ConnectI..i_,' specifications, the distributor vacuum line to the distributor. - :"Ii_ , _,_ ' Adjust the carburetor idle speed and fuel '"!"

Ii.- _ii_- " mixture. .

?_.._-;"'_I"_" • TIMING: GEARS '. ,. ' 3. Check the camshaftend play;ith_'!:iiminggear." " :',:_,_,L;_, backlash and the timing,gear runouL' ;_. Topreventpossibledamagetothe camshaft: .....,

_i;_:i,_, li_, Iobes,donotrotatethecamshaftorcrankshaft 41 Crank the engine until the timing marks are:_, •|'_ in the engine w_thout the timing gears aligned as shown.::!.,r ';.' Installed.!i' , r ' 5" Install the gear puller as shown and remove•_i_-_ " ,i_, _;: • _ " " _i

!_';';. _'i: CAMSH_=T GEAR -- METAL GEAR the camshaft gear.

ii.. Removals

_' 1. Drain_thecooling system and crankcase. Installation

,:.... 2. Removethe cylinder front cover and oil pan, If the camshaft end play, timinggear backlash :,.:_/_ follo_!ng theprocedures under Cylinder Front and/or timinggear runout were excessive, make_--,' Cove;__Removal. i! _,_',i/',. .....:•. ,, the necessary corrections before installing the" " ' ' _"_ gear.

o 1. Be sure the key and spacer are properly in- '_:i' stalled. Align the gear keyway with the key

and install the gear on the camshaft as shown.Be sure that the timing marks line up on the

" camshaft •and crankshaft gears• ...... .:,_ 2. Install the cylinder front cover and related "'

parts, following the proceduresunder Cylin-_ der Front Cover Installation.

• _._.;.

3. Fill the crankcase and cooling,_._'_tem.Start

erate the engine at fast idle andCll:eckallhose• . connections and gaskets forleaks. _

_, A$OIT-ID ':

L

Page 414: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.... :_ ' ' " "' ............ " ' .'., 'BASIC,'ENGINE_?"-L'..,:........ - .1-35 _" :; . : '

REMOVAL AND INSTALLATION (Continued)

_i'CRANKSHAFTi:GEAR": _ , .,-.. , CORE-PLUGS, "; ' ,

'_; _: _:_ _._Removal_;:/: _. :._ _-_:: _:.:•_,:_:_-._ RemovaP_;' _ ; : :

• .::: ..':.,.." " .,:,1:....Drain'the'cooling:systemand'crankcase.:Re- _..._:',: ,.':"'_To:remove;:a,:arge_:core,pug,_;drI.a12:70mm• - : .:. . ::_._.movetheradiator. • ' , " -.. -.... . " --;:. "..:.; ....: •.::e: :<"(1/2Jnch)hdle,in'_the:center,ofthe,Plugand remove

^.."h,___. = ,,___ _:J:;:,,.;._,_.. __ .- . ,..... ' ........ ,_wlt '_acutch ot,bearn pu er(Too,T59L-100-B., ,','., , emo e,[he cylmuer ,uu[ uuvuE . ., , .... , ..... ..... ' • ... ' " . . . .. • :- :.=":.,.'.:...,'t.:,_>..:l::_:and,T58L.-101-)_or.p_.=t¢outwlthalargednft punch.

.:_:3.b._:Remove;the,toilt:slingeL,.,,from:the.crankshaft:,_,_,l..:,;:,l::,,:Ona.small::core_plug_id_il[a:6113,Sm_.(314inch)hole- .,-:'-:_,...._,,_:,'::,"::,,-:";:':.Use:the;gearpuller.:,as,,sbown:and:removethe.,!;;I,::,:,:i:l::__in_the:center:c)fithe_!piug;an_Lp_yiit.out_.withasmall,,. :.,.. .... ..:,. ,,:. `_`_:_:crahkshaftLgear`:`_em_ve_the_.`key:_fr_m_the::<;`_`_._:._!:pin:-_`_J_h:{C_ean_.ah_1_iinsr3_cti_`th_`;_prug`b_re_,

•. '. :crankshaft. • I I ." . ' " . -, r . .. "......... - ' ............. '_ " ._:!_,P..fior,._!to.:Jnstalling;;a_core_plug_th.e_plugbore

: ,.,..... . ....... " : _-" ;,::interfere!_itb_the_pr:ope;rislea]iri'g_b_f_t_ie:plug.:If the .. :...,.:..-_..........:, _:,:.botei:iS::damagediit:,,,vvill,;be:necesSa.ry_,to!truethe

•, ;:_'ii:,i.Ii,.}';!!;:i:i :_.sudace_by;boring_for._tl_e,.next,specified,oversize,.plug. ,. ' " " ' "

......... Oversize ,(OS) plugs :areidentified by the OS

)ed,_imthe.,flatJocatedqn.theicup side of. the

;:_.:J:_Co.at_thff_.iplug;'ia6d/iO_K_bQ'r_et]ightiy_i,with an:_..oil-;.'"" " : .:_:4re'siStant:_('_il._gal[ey)_.Ot#:_ater=r,e_is't&nt(cooiing

_t':jacl_et)i,sealei:=ahd:.nsta!J;ff_followin_j"-th'eprocedure,:,.;for.:cup_pe_.0r>;expansio0-,type_below:

.Installation ..... ' .- - .... ". -

;,,_'flange_;ed_ae_6ut_N:ar_l::rhe_m_imoi_diameterof .:'_

1. • Install the key in the crankshaftkeyway. Install - thisplug is locatedat the outer edge of the flange: -• • ' The flangeon cup-type plugs flares outward withthe crankshaft gear, using the tool shown, the largest diameter at the outer (sealing) edge.Install the oil slinger.

It is imperative to pull the plug into the me-2. Replace the crankshaft front oil seal and in- chinedborebyusing a properly designedtool.

stallthecylinderfrontcover,followingthepro- Under,no circumstances is the plug to beceduresunder CylinderFrontCover. driven intothe boreusing a tool that contacts

3. Installthe radiator, the flange. This method will damage the seal-

4. Fill the crankcase and..the.:cooling_systems:,,: ing edgeand will result in leakageand/or plug: .Start the, engine.and:_;_eck:_all;gaske{s:and:.ii • blow out.

hoseconnectioh_f6_:lea.E'S:-Adjust.tbe:ignition:.; The flanged (trailing)edge mustbe below thetiming, chamferededgeof thebore to effectivelyseal the

pluggedbore.

TIMINGMARKS_= If thecoreplugreplacingtoolhasa depthseat-

. - .,,_ ii!:ii_!1_ _ ing surface,do not seat the tool against a non-machined (casting) surface.

_,_ '_;: _ *__" " _"_'_'_::"_i'___1 Expansion-Type

_liiii_ i!_ .....!i!"_.!':i: _.... _ .-. Expansion-typecoreplugsare installedwiththe

,,ii,,___/ .... r.__._:::_ii:'!'! flanged edge inward The maximum diameterofthisplug is locatedat the base of the flange with

: _ ' i_: ...........:... ........ _ the flange flaring inward.

It is Imperative to push or drive the plug intoi the machinedbore using a properly designed

• t tool. Under no circumstancesis the plug to be.... drivenusing_atoolthatcontacts the crownedpor-r

CRANKSHAFTSPROCKET tionof the plug.This methodwill expand the plugREP_CERTOOL priortoinstallationandmaydamagethe plugand/

A2827-1D or plugbore.

Page 415: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•REMOVALAND:iNSTALLATION(Continued),_,

;" :,.::'wheninstalledthe:trailing(maximum)_diameter'_,:;."::: if the core.plug replaclng tool_.-:hasa depth-,. ,..,." :..!..._..:_:::,:.must_be'.below,.!he,chamfered_?edgb_of_the_'bote;to-_,..}+_":'i+seating,surface;do,not :seat:the:tool+againsta;_i": : .. + +..., . • .;...i;,_::,v;;effectively_seaJ:!the'_plugged;Ioore:_9_+;_;._:.;_._.:_:+_;:_;._u_<_`_::_!_:.:_+:_n_n_mach_ned._(_ast_ng)+surface_,:;._!_::_._<.::.: v _,_+_: ." "..; " ',",

• i:i:_ <.. SEALtNG

!i'_. . EDGE": '_ _ BEFORE -.

_ INSTALLATION "'i

I_'_'/_=l_.I , CUP TYPE CORE

+ BEFORE

_;:. " :_:_i I/ / / /I _ _ " INSTALLATIONk"///A • TYPE,. = . .,: _'"' :,_;- _ PLUG "

,. • . , ,

+x x x x x x x x+,ir,x_xJ

++,, +_++_+.

::_ + +

+-+_+". •,EXPANSION TYPE PLUG EXPANSION TYPE CORE

PLUG REPLACER TOOL

A 2735. BI

.. ++ ;._

Page 416: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" _" "'- :'"" : :"' .....' • : "'::_BASIC:_ENGINE::_':' " " 1_37"'"t.:.:: .'

.. .REMOVAL AND, INSTALLATION. (Continued) , .

PAN:,_ ' PUMP:.!,,,.01L:: .. : .... 01L.. -,

........... ,,, ......... _ Removal::,,'" " ' ' ;'

. .'' , ';r 1..;: Drainthe._crankcase.•.... : r " :'"1,. _' -:Remove;,the_oil;pamfollowing_theprocedures.... .:: ':under Oil"Pan_Removal.•,. : , :.:._,.;:.:,-:2;.,_.:Remove_the,oil:pan.attachingbolts.-,Rem0ve/ .... .,:.....::,.:'.:,'_,;..;.,i_..._::_:_:_theLoili_pump;inlet_:tube_attaching:bolts./Re,',..:."-_._,_2:..._....... Bemove.the............o I pump_attachm:...... "bots-"Discard"' ,:;" ,. ".: -'..::,,:,'i_:':-::._move.theJnet tube'.a_ndscr,een assemblyfrom: : ..... ; ' ' ' ' ' ' g ••r:_''' the:gasket. - ' ,- ".

., .._tl_e:oil,pumpandrleaveit in.thebottomof.theoil,,................: ; _.:.:'.:pan:_Remove_:the oil,'pan.and :gaskets..;Re- . ,

• . /" : ;:_"move_the_inlet-tube and"screen:'from:.theoil '• pan. ..

, Installation

•, ....:-._..,,..,__;:.- ;:_':.1_,_Cleanlhe:gasket_surfaces;of_Lthe:oil:pump;c .... 'i,_%::__Pan:and;cylinderblock_._Remove_tb:eirear,main:_..,.. ..,"

• ". , . :: ':_""_..:",._:':'_beaiingcap_to'oil_pan_sea.;andcylinder:front_',,*' , .. '. . .-.:.J": :._.,_ico_er"to_oilpan:seal:Cleanthe.seal.grooves;. • . " " . ,

....... " .i,.2::o.Apply oil-.resistant seale_ B5A-19554-A or ,•:_;_:.,.,.::_!:,:equiv,alent(inithe_cavities:.between:.the bearing ::'i '

...'_..:.'. -:....,_: .::_::i!;_.--,'cap:_ar_d:cylinder_block.;,,Install_,a_new_seal.in , . .......:-:. ', '_ _',"_:,_,:_;the:r_ear,main;bearing_cap.and:appya_beadof :.:" ...:_'. , ;:-

............. :'_?.::"oil_resistantsealer.to the-.tapered'endsof.the .." seal.

. _ ;_. ,' __ ::;'_=_= F RON T• , APPLY(BEADoF ,/

" • ',, ,,SEAUER AS SHOWN,;",RE'AR,MAIN BEARINGCAP ' " ' ' "

' ," - :/ '. '_,'A216'4;A' _"

Installation

1. Primethe oilpumpbyfillingthe inletopeningwith oil and rotatethe pump shaft until oilemerges from the outlet opening.

' " PRIoRAPPLYToSEALERINsTALLINGINCAVITIESsEAL OILSEA_,. 2. ' Coat a newoil pump gasket with oil-resistantsealer .and position it'on the oil pump.A2840-1A

3. Install the oil pump on the cylinder block.3. Installnew side gaskets on the oil panwith oil- Torque the attaching bolts to specifications.

resistant sealer D7AZ-19B508-A or equiv-.... • ,..., ..- ,.:alent,,.P0sition._a,new .oil-pan'to'cylinder,'front

cover seal on the oil pan.

4.. Clean the inlet tube and screenassembly andplace it in the oil pan. CRANKSHAFT REAR OIL SEAL

5. Position.theoilpanunder the engine.Install,the inlettube andscreenassemblyonthe oil Ifthecrankshaftrearoilseal replacementisthepumpwitha new.gasket. Torquethe screws onlyoperationbeingperformed,itcan bedoneasto specifications.Positionthe oilpanagainst detailedinthe followingprocedure.If the oil sealthe cylinderblock and install the attaching Is being replaced In conjunction with a rearbolts. Torque the bolts in sequence to mainbearing replacement, theengine mustbespecifications. Installed on a work stand.

..... 6. Fillthecrankcase and coolingsystem.

7. Startthe engineandcheckforcoolantandoilleaks.

Page 417: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• . • , _ - . , . ,. _ , .4. ,,. _ . _.; _.,._, ..... . • •• ., .

• REMOVALAND.INSTALLATION(Continued), ......

I

A2842-2C

:_,..

__ RemovaJi_i" blocksurface.Remove the tool and inspect,_i'_ 1. Remo_vethe starter, the seal to be sure it was not damaged "

' 2. R_m_vetheP:3".O.orpressureplateandcov- during installation._ er assemblyand the clutch disc. 2. Installthe engine rear cover plate. Position•_ - the flywheel on the crankshaft flange. Coat '_.,, 3. Rem61vethe flywheel attaching bolts and re- the threads of the flywheel attaching bolts

move, the flywheel and engine rear cover with oil-resistant sealer and install, the _':,_ plate_, bolts.Torquethe bolts insequence across

4. :Use_n awl to punch_two:holes!id_the_crank- from each other to specifications.

'i;_:_ -shaft rear oil seal. Punch the holes on,op- 3. Installthe clutch disc andthe pressure plate• .,._,positesides of the crankshaft andjust above assembly, _;_'i_the bearing cap to cylinder block split line.Install a sheet metal screw in each hole. Usetwo large screwdrivers or small pry bars andpry against both screws at the same time to

....removethe crankshaftrear oil seal. It may be ._• necessary to place small blocks of wood

against the cylinderblock toprovidea,fLJIcrum TooI-T65L-_70!.Apointforthe pry bars.Use caution through-

, out this procedure to avoid scratching or _; iotherwise damaging the crankshaft oilsealsurface.

5. Clean the oil seal recess in the cylinder block . ,,and main bearing cap. _ ,:__:;_:__,i ,t;.__,,, _,,,

......Installation ._,,

1. Clean, inspect and,polish the rear oil sealrubbing surface on the crankshaft. Coata _.,newoil seal andthe crankshaftwith a lightfilmof engine oil. Start the seal in the recess andinstall it with the tool as shown. Keep the toolstraight with the centerline of the crankshaftand install the seal until the tool contacts the.....

Page 418: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' ",._. . .... ;._:.1"39 ...... :' ' 1-39'_':..... ' . _: .. ' .:BASIC'ENGINE:,.L_,_:_' . _ "= r

.... iREMOVAL AND INSTALLATION. (Continued)

.;'_:'.:MAIN_BEARING::'.... -_ -,' .... . nal.WithToo1:6331positioned._in/the.oil_hble,' .. ,-ii_,.;._,,,, ,.,_.,,,; _,........ ..- _..-, • .. ..... :_ : -. ,:., _. rotate..:th.e:crankshaft;slowly;in_,the;_opposite:.,:._:: /_;._.:....... .Do',not_fileo'r,lap_beai.ing-cdps_'orUs'e_shims.... directionof:enginerotationuntilthebearingis .......

- -....:.'.., . -.'"toobtainthe:proper, bearing,clearance..- ,, -: • ,.seated.Remove_thetool.

.,",, . ;_-:_: _, !..:'_;:-.,..,.:._:Bearingsare I.available for :.sbrvice_in,stan: ........':!,i_°_..;:;Select_fit_;the!beariogfor_.proper_:clearance:_: -_._ -', _:_,_: _;:i_3;_'_:dard,sizes_0r.'o_001;:and_0,002inchUndefsizb,'_'*;?;_;_'_:,fo!low!ng_procedur.eSgiyen_undelrEittingMain _.,, -,__ _,_--'_'__:,_._,'%Refer,,to_the,Parts_Catalog_or:availablesizes.."/':':_:_:::!_ahd_ConP,ec!!hg,,.R0dBearjngs_:0ni:page'1_-.19_::, '_,'

.:"."-i:i_.:il2:.:I}!iI£:i;i ;_;'_';_Unders!ze_bearJngs2are:av''ailab!e:.fog_use:.,On_.-,,._.::_:;_2.,_A_e_i:t_e:beglriO_];h_asibee_nlfi_ed;,.,a'pplya light . ... :_:::;7journais_tnat,nave_:oeen::retin=snea.,.. ' _..-.-..- -._.,,:,-."_cx_at_'of;ei_gine;0il_tb;ti_b,'joUmal:;add_,bearings_.' ,-

. .-..: :.:: ,',_,_.:.-:?_:.i:_._.lf..the:rear:main:bearing.is!tobe,replaced;it.,:;:__.,.::;::;_!hen:_install._the_bear,i.0g:;caPii::,lTorquethe cap. ' "". .,-. - ,,_: '.:,_;:.,_1_;:::,::;:,will:benecessary;to:removetheengine,:install.. - :::;>.".,o_lts:,To!:speCirications:: .' ../::! ,_.;;,_': "

_. it on a work stand, replace the mare bearm 3 ' .. :.,.:-,, ..... ..... ....... .... . !. ,.... !. g.:-_:__._,+,:-.:_!iRepeat_the!;pr0cedure-f0rithe'mm'ainngbear- :..... ; ........ ._I.._.,...,andreplace the, crankshaft, rear_,.oJl_seal..-_. ,.;.,;........;,._:nos_.that,_,re(_uire.renacement:;._.:::,;;., ._ . , . ,.

•'-••,•. -i i• '; i.'i:J_:_,_;_i:Removal.::•::::,':,!:-!_:i::,:"i.:,.,,_:/..:.,,,,.;:'_i"::. ;._.:.,,!:y: ::,":,'._•...,:-i.4,.:'-,:_"lf_the,thrust_bear,ing,cap_.(N0_5mainbearingi •;":, , has been removed nsta, t as fo ows

,_":---..:,:-"', i-,i-/., -_:ol.;;_:Draimthe:crankcase:_Remove.theoil,pan and'i: :, .,'.', , . " " " , . : ..... "

.... - .. " 1'- ,_" _-_::-oil.pump;following-the procedure' under, Oil.... .- : _.....•Installthe_'thrustb_aring'cap with the bolts - "J,,...._ , Pan,Removal. -, , • , " , ',, ,'.... _,,,.:.'.._,finger,-tight:.,!_Pry;._,th_e_crankshaft_,forward• •

::_-:.._ ,_:_:'. ....;-.J_,_!,,_:._..:,2.-,:.:Replaceone;bearing_at,at_me;leaving,the-:-_--,,._,.,_%agamst_the,thrust-;s,uffpceo,f,,theupper:half:of - .-_,""_;.... _..- .:......J_-','_:__';_";-,;;_othetbearings.securely4astened :-Remove:::::'',:_?_:_!,'.the_bearingEH01d!,the_:'c_,a.nkShaffffsrwardand. '....

'" " ""_"" t-'_-i ,-::'--:;:.,the,main':bbaringCap'to:which-newbearings_'_:_.:"_::._:p_the:_th'riJst_blbari_g:!iCap,;to:the"r_.ar.:,ThiswillI _ _r_.tn.h_, inst_ll_.rl ....... ' ' : " _,_a g_,[he_th_us[suoaces_of_bot'-havesof the

- I " 3' Inse h .... ' ..... : ' ' .:. _,.;:.;;bearingJ_etain_the_forward_pressureonthe "._--.,,.7,. . :._,,_.,':iI,:7:-..,..'.._i...rt t eluppe.Ybearing:remover(,Tool633! ) . 7: ,,",,_;:_,cr_:an_ksha'f:ti:_i_orqlu',e_::th_,i,c._a'_)', bolts, to, _ ,,.,, _-:.................., .......ln_me.,Oll.nOle.:ln:me.cranKsnar_journal.:, ....... ./'_",,,,speclflcatlons." ' ._ " '.-. ....,----. 'I ..,i•.,,.,':',,! ._._,.__.4._',-_,_Botateithe_,cr_ankshaft_:in.,thedr_ection,of_en,-,:, _.-, _,, '"= ,Lo' _,-4,_:i_-.,,.L'i_.;.;='.io,_..,;__,.., _ _',", •_

...... • ._,;-;-......',-,,gme.rotat_on-"to-rorce.tne,Dearngout or"tne ...... " 'WOrks" i_-": a " - " " -"' " "" " " - "-.... :........ _'i,., : • " "', ". ., -., ,: . , ::;.;,-_::,:._:%, ,: za 0),.: pply_.:a:;oeao'_ot:on-reslstanz.-...<. ,, _;D OCK

• : " '_ 5:?' Cleanthe crankshaft journal:When replacing: " ingcap saddle the full lengthof thesaddle. _._.- standard bearings,with newbearings,-it is._ Be sure the main bearing is fitted .andthe ' ._;

good practice to first try to obtain the proper cap bolts torqued to specifications before _ ,,_clearancewith standardbearingsor a corn- installingthe new crankshaft rear oil seal.

bination.ofa standardbearing and a 0.001 or 6. Clean the oil pump inlettube screen. Prime0.002 inch undersizebearing, theoilpumpbyfillingtheinletopeningwithoil

Installation androtatethepumpshaftuntiltheoilemerges

1. The upper and lower bead ng halves are from theoutletopening.not interChange_,bie.:i;'Fhe:_u[)per:_ihaifyis: 7 :lnsta I the oilpumpandoil pan, followingthedrilledand:gmovedto_provideent_yof'oil. _'. procedureunderOil Pan Installation:

To install theupper, main_beariflg,;place:the 8. Fillthe crankcase and coolingsystem.Startplainendof the bearingover.theshaft'onthelockingtang,side of the block and partially the engineand check for oil pressure.Oper-

ate theengineat fastidleandcheckforoiland• ,'_..,,:__install,the bearing so that.Tool 6331 can be ' .:• inserted in.the oil hole in the crankshaft jour- coolant leaks.

Page 419: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

I_,,.... • ....',.., .... :o; I_._!'_,_iBASIG'i_,'ENGINE_i_,_;:;'":.',_/ :,"..... 140 _" ' "'_ '•'" .

REMOVALAND. INSTALLATION, (Continued):,i

'r.'I,_coNNEcTiNG_RODI_BEARING' ,,i,,', i . i.' Instaiiation. _. • _ ' • " .i ; " " I ' _'•i .......:'__:_'_,.,.",i ..... ' ' ._ _ _. ,.. ,, , ,;; ._., ' _,., .1,!...,Install,:th'e_,bearing:"inSerts_'_in:;the_connecting,_.,,'._".1.;_"_/_"Nem°va!:,i: .." "_" .i :i :_:'i,,,',,i ii,,.!_!:_.,i_,,,,.i:,_ ' ,,,,i".:,:'"._'_.;'," rod 'and ¢ap:.wi'th"tl'ie..tangsffittedfin,the"slotS,_'_",'_'I_''_ '

.;_,' 1. Drain:the crankcase. Remove the oil pan andoil pump following the procedure under Oil 2. Pull the connecting rod assembly down firmly

° Pan Removal, ,.on the crankshaft journal._,' _Fit the bearing following procedures given un- "i, 1 2. Turn_thecrankshaftuntil,theconnecting rodto

......... whicl_inew bearings are to befitteci is down. der Fitting Main and Connecting Rod Bearings.• :-. Rem0vethe connectingrod cap. Remove the 3. After the bearing has been fitted, clean and . -__:., beari'_g inserts from the rod.and cap. apply a light coat of engine 0il to the journal .-,._ ,_ _'

3. Be s_:'rethe bearing inserts and the bearing and bearings. Install the connecting rod cap'_._ bore_i_r_the connecting rod and cap are clean, and torque the nuts to specifications._'__" Forei_inmaterial under the inserts will distort 4. Repeat the procedure for the remaining con- ' • '_',_ , ,.the;be'aring:andcause, affailure.,, nectmg rodsthat, requ_re.,newb_a:nngs.:.... ' ,

: 4':_:':_iCleanthei crankshaft:jour,na:l!'.When_repla¢-".:".:" 51:'-,Installtheoil-pan and oil pump,i';ifloilowing:'the;:,:_ .,,_:..... ing.standard bearings withnewbearings, . procedures,unde_ Oil. Pan,Installation in this

.iiii_:;,_. ' :,itis, good practiceto:first,tryto obtainthe .' : . section._, .

.,._ proper clearance with standard bearings. 6. Fill the crankcase and cooling system. Start_, Refer t_ipage 1-14 for the cleaning and inspec- the engine and check for oil pressure. Oper-_;_i_:"tion procedures. _ atethe engine at fast idle andcheck foroil and ,-..... _ coolantleaks.

, , "::::::_ THRUST BEARING THRUST 5_;_

PRY CRANKSHAFT FORWARD PRY CAP BACKWARD TIGHTEN CAP A283,4-A

.. PISTONS AND CONNECTING .RODS the upperend of the cylinderborewith a ridgeRemoval ?'':.......cutter.Followthe instructionsfurnisl_edby the ....... , , _,........

•'"_,_tool manufactu'rer:,Never cot into the"ring'.,'_'.!_,1. Drain the cooling system and the crankcase. ' •travel area in excess of 0.74 mm (1/32 inch)

2. Refer to Cylinder Head Removal and remove when removing ridges.

,,.. the cylinder head and related parts. 5. Make sure allconnecting rod caps are marked _.,.,,,3. Remove the oil pan following the procedure so that they can be installed in their original :_

under Oil Pan Removal. Remove the oil pump• positions. Remove the connecting rod cap.inlet tube and the oil pump. 6, Pushthe connecting rod and piston assembly ....

4. Turn the crankshaft until the piston to be re- .- out the top of the cylinder with the handle end_: moved is at the bottom of the stroke and place of a hammer. Avoid damage to the crankshaft,,_ a cloth on the piston bead to collect the cut- journal or the cylinder wall when removing thei.' tings. Removeany ridge and/or deposits from piston and rod.

Page 420: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

_ - ,. ,_ /BASIC'ENGINE,.:." 1-41.... _.

:,REMO VAIE.:AND:rlNSTALLATION (Continued)

:..,. .....: ...._ ,. _:_i_:i._.!_:.1:;:_:._C_e_ni_tbe_i_p:um_p_in_et;t_)e_scr`een._ap_d_the;.::_.:.-_::':"-_":_:_"_'_""_'_'_"'::..... : oil panand block gasketsurfaces: ' ,

• ". ::: ;'. :o:2,:/::..Oil,the,pistonrings;pistons andcylinder.walls• ;..:,":with. ght..engne:o. ,. .. ' _ :", :':"

•. ,..',_ ............t!"-::_3i.-_:Be:sure_to=Install,the,pistons i" ' __:......:-_-__:':',_ :_,,::.::,-,_cylinders=from,-which:they_were-'.removed

"" :_,:.._.:.::',"::or:!o:whlch;:theywere_fitted...:T:lie:connect-::_:,:::."::..':":-_:' ::'_i_i:_.:, :_' "_:,.'.::_:::_',jng_rod_.sand_',bearlng,caps_are;,numbered_-.:,i._:

ii.i. :i : .... " " :':_:fr°m:r:l_t°:'6:':beginningat:'the:fr°nt of the .-,-:. ,:::'"/.._:.!:-_engine;_The:numberonthe'Connectin,

__ _, .....'" _"_:.:.,::?':..'__,_;connectlng:, ::'."": ""':';. , _:'!:'.-..;::,_._-oneblock_or_¢ylinder_.t0an0ther,newbear-_:_:.,."

. . . . :.. :...-;_'::_Ings"should be fitted .andthe connecting . -.. :_NOTCH_TOFRONTOFENGINE' : :,."''_ ="'rod.should_be"numbered 'to .correspond _.. I

-. "_. ....."with the:newcylinder:number. " " '_'""_, _':" _''" •""_"' " _: _": I:':_".,:_:4_.-:_:Makesure:themng:aaps'areproper y,:spaced.......... . .. ::' .. _,.:::..: :.'_...::.-':..-,.,: :;.,,: _ , ' ,

I

.. " - ? ::::"::_-'_%._.,:_:;_;.aroundthe circumference of.thepiston._:Othe. _':! "._'_'Ci_hgl_t_:coat_'°f_e_gme_°l!_'t_-:!he_j°u.rna_ana '........ :.,.._._ .:...:::_rings.then:install a_piston:ringcompressoron ._.beadngs.'..... ' • ' '.:..... ._- - ._::.:.:_.'_::the,.;piston.,Make_-_sure:that_the_indentationin ,,, .:-7."::"_um_;the_crankshaff_th_ow_to:-the_bottomof its

............... ,:,_,:..,_,_::_.thet_ead_of_,.the_piston,s_toward_the_front;_.then_,,._:-:,,_:._:,:st_ol_e_then..-pi_sh_,the_pistoniall_the!:way_down.........,.., ......: ....:i._

_.'_.`.".::_:1::_`t_p_:_f`the;cy_inde_._Be!su_e_t_:_guide`_he:c_n-_.S_;`.::_:,_`)_._c.iipi_:r_rqugJ:the:_n_uts:£_.`speeifieati_ns....:., : :.,.,: ,_4:.;'::,:_::i:2.,:nectingrodsto:avoiddamagingthe cr,ankshaft ::

,: , . journas " '....._._ ...." 'blieshave been installed,check the'connect- ' '5. Checktheclearanceofeachbearingfollowing ' '. ing rod side clearance on each crankshaft

the'procedure under Connecting.RodBearing : journal. "Replacement.

9. Prime the oil pump by filling the inlet Openingwith oil and rotate the pump shaft until oilemergesfrom theoutlet opening; Install theoilpump and the oil pumpinlet tube. Install theoilpan and related parts.

OIL RING SPACER

- t .......... OI'LRII_G . ," ' _ .... ' "OiL:RING _', .........

MENT,' . FEELER GAUGE

.::_.....

/ .....COMPRESSION RING _t COMPRESSION RING

|

FRONT

Page 421: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

rr REMOVAL.AND..INSTALLATION(Continued):. ",

| ' " : :"_:"''t:'the:cylinder'head_and_related;pa_ts'"Adjust'th'e;i:?':"';':";i Operate'the:engineat'fast;idle_and_check.for::, r I':'' :"'_ _ : ' ' i'''::"'

I;_i '_i";"11. Fill and bleed the cooling system. Fill the 13. Operate the eng ne until temperatures have'-i" ,i. crankcase, stabilized. Check and adjust the ignition tim- . ..

I,i:_i. ',; i:i ing. Adjust the engine idle speed and.fuel ,,_., _:i__

i.ili , _ ,_!:_, . mixture. ' "

:" CRANKSHAFT

i The crankshaft and related parts are shown, pan,gaskets andseals. Removethe oil pump

:; "" '_ ' and inlet tubeassembly.Discard,,th_oil-pump !_":_"_ iii':i:';,Removal_,_ gasket: " ' :,_1 " " " :,_"::_;_:_:_;_i:_i:_i.: :Install' ' ' '..... " " ::'S

the,engine':,0na,workstand. Remove : 7: Use an awl to punch•two holes iff.the crank-., the.spark plugs to alloweasy rotationof the. shaft .rear oil Seal..Punch the holes' on op-_....:_:,:i:,' !_i::,_ .crankshaft.

... :-__ .,,, positeSidesof the crankshaftand just above_::;,i_-;::,!:,';i 2. Rcm0!v_the oil level dipstick, the,bearing cap to cylinder block split line._,:.... ; '_-. Installa sheet metal screwin each hole. Use;.,:. •, : 3. Rem_qethecrankshaft damper reta n ng cap-.... two large screwdrivers or small pry bars and,...... :'. screw!_andlock washer. Remove the crank- pry against both screws at the same time to,,, shaft,damper.,,: removethe crankshaft rear oil seal. It may be_:._, , . 4. Remove the cylinder front cover and gasket, necessary to place small blocks of wood

_;;,: :,.,:.;5. Remdge the flywheel and engine rear cover against thecylinder block to providea fulcrum:_, ,,;_ plate.i:_ point for the pry bars. Use caution through-

:.. out this procedure to avoid scratching or _:i:,__""_ :_ 6. Turn tl_eengineon the workstand so that the otherwise damaging crankshaft oil seal:.:!_.i:/..... _i'..: bottom"of the engineis •U'lb!_:Remove,the oil surface.

CLUTCH PI LOT

BEARING- 7600 BOLT-6379

• _ \REAR OIL SEAL-670t

\CRANKSHAFT GEAR-6306 _ _;_ _*"':" _.....

.... •,'6A338,t_,,,_ • , -, _ , . • _ . . / . .,

"'o _%%."_._._ ..... ' FLYWHEEL" , ._"

.... MA.N.E.R,NCA..

•, _;-_" I')AMPE R-6316 FRONT '

A2843-2C

Page 422: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

- "°._REMOVAL_ANDJ NSTALl_ATION.(Continued) .....

._Make_,sure_allbearing_,_caPs:_(main:and:,con,.o,.-._ 8!_ •Check::the_clearance:_.of_each;,:m,_in_",bearing... ', .,_:,.:::._':_'::._,:,following!procedures:given:under:EittingMain,",

.installed,in,their originallocations: Turn ithe .., _:'andConnecting-RodBearings. ,,,,... . . • .

,_crankshaffuntillheconnecting rod from:which ........ '.. ".....; i ,_.:the:tap'is' beingTemoved is:at't_e',bott0_ of.. '"_;9_ :_After,,:thiJ,_beafings_ha_/e",been,ihsta'lled,apply

" ""' "; - - o_._.......,_ the'stroke','RemnVe"'thp._nnnn_.rtin'n-rnd_r._n-,..........., .;,,ahght.,coatof;heavy engnne,oll to,the journals,........._ __nd'be=..... _,D.._h_*ho,,,,..... ,_,,,__,_,_.... ,_.................and,bear,mgs.Jnstall,all.the.,beanngcaps. ex.

• • _ _,-JLIII n_.;I, l, Ugl I TLI I_ _,._t,.#l II I_q,.,,LII I_ 4iqJu O.IIU _ . , . - -- , - • , , , , .

-: ;:"::,:-_,;'piston "a_ssem'blyo'up,in,,the;:cylinde_iDo'_not'`_'""_' :_:cept..thethrust bear,a0g:cap(No.,Sbearnng).Be - ..-. _.... ""-.'::"turnthe.rr_nk-_h_ft"r,_mnn=*=n......... ,_,.a°,,_ ';; ",;:_.:,sure'_ thaL'ithe,_main_beating.:caps _are in-

-..:'::. '.' _.'- '-'."_:-:_ '";-_th__.r_H::h_l_=,m_u,;:el&_._L;_;- ;: ,i,_,_,;.."_d,,'._ '_:_,._ _-;_,'stalled;3n_]tl_elr_orlginal_,_locatlons."'_Orque' , " ',-

-, ............... •_--_,-'_:-!]oUrnals_Repeatths;prOce-dure',:an_dTer:n()ve' ": _':";_:"_'me'pean,,n-g_.a.P::_D'q!_,s,_]°_sp_eclqcaz!ons" . "- , ..... ., ,:all,connectlng._rod,caps......... , .... " _......:-_:10.,_,.,Install:,the_thrust,_beanng_,,cap_,wnth,the ..bolts

-_- -:-.,:-.::.'9.,;';,.Remove;the_lutch:pd0t_busbLn.g_,if;qecess'a_.,..,.r ....... .._,finger,,t!ght.., - :._,,. - ,., .,,-,, ...-,_, ...._:;' ""10"_A n,_th_:."mi" :'" " "' _.... ;_ : ::......"" " _ ': 11_Pry'the'crankshaft;forwardag ainst'thethrust " ' :": ''• -,,.:,.,,,_,_.:.. g ,, e,:tl ng.marks:.-Remove:the-crank__,,,,'...- .: • ,. - . . • . , • . ,,- . ,.

..... :,shaft'gear. - .... ,, _, • " _ - .,_sunace:ot_theuppernalt of-the,;oearing.. _ .

•-:'l,l::;Removethemainbearing'capsand bearings,;'_ " "12:-Holdthecrankshaft forward and.prythe thrust ." . :bearing Capr_tb,.therear_"This will align'the

_:_._._-12.,:;Carefu!lyliftthe_crankshaffout of:the cylinder::,:,.,_:_:°:_:_;_th_ust_su_d_ac_s_f_b_th_ha!_e_fiithe`bear_ng"........ _,block_,sothat.the_thrust_bearng-surfaces are , _ . , . - . . , ,. ." : n ' _n__d .......... "" ....... :...._'"_"_13-_Retain_the_ro_ard_pr.essute_Or_me.cranK-"..... n_t dam_=__. ' - • , ......... . .,:; . _._-_......,_........ ,_............. ,,_-,_.

• . .... : .... -:.-,; .,--shaft_,_ofque_,the.cap,,bolts.,tospecff_catnons. ...:,..........,.,.,:_Handlethe crankshaft,with care,to avoid

........ -;:--_:p,ossible_fracture:ordamage .toTtlle .... ':.,.44C_.Check_;_the"_'cra_ksh'aft_end_play:"_";;".:" '.,... , .' -- -.,-_."_,-finished::surfaces._,-:.:....... ':•- : ,;-,. .... _'__..=15:.,_,......f,_tl_e.:end_''__;p....ay_exceeds._the'..... _ _ " Weariiimit.,_mplace"

.......... ;:. _,_,:#Refer_to::l_a_e_1,.12;for':the_dlean'inci,:and:_irl_..-:-,,..;_;._:,,::_the:othr_ust_bear,ing_._lf.;the;,end:,play,-:is;lessthan,.,

,i:"_._;_;spectioniprocedures.Be:sure:tl_e::bilTsealSur--:,:::_._:__.!he.,:minimum.,limiti'._inspect_the.,,th[ust,bearing, .,, _ ,. ,,.._.• ,,, faces:,o_-the, crankshaft a'nd _,¢t-ankshaft,.:.:_.,,,-_;,',;aces_ror,;:sc_'atches';'_buri's;_,nicks,_or_foreign." .-..i .-_:

:,.!._i'_damper,are_grogerlv.cleaned '"': _ :; :'"::-_ _-_;i!_:_:_`i_i:_:ma_`er_:._f_the_th_u_st:face's_`_`_rei_(_ot_:damaged:°r' ' ::.' "......... .. ,'.. ':-... -. . •.. : . .:.. . ,,.,,:-:•di_,-tll_y__615a_61y_:i_ed:;_e_ii_iing:,lnstaii!'_-'::; :..,_;,:,_,,_,

.... ,no rermtsnjournaus,aress.minorimperrec- the thrust bearing and align the faces follow-tions, etc.,rrefer,to page1-19;, ing the recommended procedure (steps 8Installation through 11).Then check the end play.

1. Remove the main bearing inserts from the 16. Coat a new crankshaft rear oil seal with oil andinstall it. Inspect the seal to be sure it was not

block and bearing caps. •damaged during installation.2. Removethe bearing insertsfrom the connect-

ing rod caps. 17. Install the bearing inserts in the connectingrods and caps. Check the clearance of each

3._ Cleanthe crankshaft'rearo ,seal;recess_inthe:, bearing following the procedure under-Con-.. cylinder'bldck_:and,rear_main_bearng,,:cap-,_::.... necting Rod Bearing Replacement.

4. If the crankshaft-main bearing journals_have', 18. If the bearing clearances are to specifications,been refinishedto a definite undersize, insta ,, • apply a light coat of engine oil .tothe journals

.. the,correct undersize,bearings: Be sure the and bearings...... -_.:._," . -:.bearing inserts and bearing_boresareclean.

.• Foreign material.under the-inserts will distort. 19. Turn the crankshaft throw to the bottom of itsthe bearing and cause a failure., stroke ancl pull the piston allthe waydown

until the connecting rod bear,ing seats on the5. Placethe upper main bearing inserts in posi- ,- crankshaftjoumal.

tion inthe bore with thetang fitting.in the slot ..•- provided.Be_surethe oil holes in.the ,bearing...... .,20..Install the connecting,rodcap:and torque the

inserts are aligned with the oil holes in the nuts to specifications.cylinder block transverse webs. 21. After the piston and connecting rod assem-

6. Install the lower main bearinginserts in the blies have beeninstalled, check the connect-•bearing caps with the tang fitted in the slot. ing rod side clearance on each crankshaft

journal7. Carefully lower the crankshaft into.place. Be

•:careful .not .to• damage, the bearing 22. Clean the oil pan, oil .pump and oil.pump..,surfaces. , screen. "

Page 423: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

REMOVAL AND INSTALLATION(Continued):,.

:": 23. Jnstall. the)iniet.tUbe;"andscreen_:..onthe.oii i_: ' 28..Insiaila.newcrankshaft:front.oil:,sealdn theii:/ ,i 'i ',...,:,_::!!pump:_`;Prime7the_i_:i_pump_by_fi_ing_`_the`;in_et_i_::::`.i:_.:_;_``cy_inder`_fr._nt'_._c_ver:;.i_nsta_:_the:;cy_inder;fr_nt_i;:i_:__-

',,:_ii,, 'epei ing,_,with_'_oil:.':'add,:;rotat'e:_:th'e_pUmpi_shaftt':,:._;i:",::_!_::,:_::;_cover_and_cranksh_aft,-_damper-/_"":,_:"_._:.._ :::.-.::i:.:.., i_i.i!,;:-) :'r"::."' ',"';:',

, ,:;- until ol!.emerges from the outlet opening. In- 29. Apply oil-resistant sealer in the cavities be-' _ stall itwith a new gasket. :Torquetheattaching

._-i_. bolts'to specifications, tween the bearing cap and cylinder block. In- . ._, ,_._. f_ .. stall a new seal in the rear main bearing cap .::..:. • .:,.:-,/_,!,: 24. Installi:theclutch pilot.bushing. ,_.; and apply a bead of oil-resistant sealer to the:,:_':::25. Turn the engine on the work stand so that the tapered ends of the seal. Install new side gas-

.::,ii,' rear df':the._,engine isup. Position the engine ketsOnpositionthe.Oilanew panoilpanWithto°il'resistantthecylinderSealer'front- " 'rear cover plate on the cylinder block. Positioncover seal on the oil pan and install the oil pan.the flywheel on the crankshaft, Coat the

_ili! threa_s of the attaching bolts with oil- 30. Install the oil level dipstick.resistant sealer and install the bolts.

::: Torque_thebolts to specifications. 31. Removethe enginefromthe wo_;,stand.Fill:.'ii,i,"" .: . .. .. , : .... ,.. crankcase,:check,the:ignition,timi!ngand:'ad-'_''i:_.:::" _' '_",._"',._.26:_._Zurn,the,engin(_.on.the,work:;stand_'so!that;the.....".::': just .if necessary:,.... ::i _.:;._-.:_,..::.'!-:i:, front end is up. 32. Check the ignition timing.and adjust if.!i:: 27.;InstalLithe,crankshaft'gearfollowing the:pro-. - necessary." cedut_':,underTiming Gear Installation._°..

•,':_ CAMSHAFT. BEARING mandrel.With the expandingcollet collapsed," installthecolletassemblyin thecamshaft

, _,;:' Camshaft bearings are available pre-finished to bearing and tighten the backup nut on the,-:.i:..size for standard and 0.381mm (0.015 inch)un-• -- dersize journal diameters, expanding mandrel until the collet fits the '....... ' . camshaft bearing., . • .

:., Removal "5. Assemble the puller screw and extension (if

"" 1. Mount the engine on a work stand: necessary) as shown and install on the ex-panding mandrel. Wrap a cloth around the _'

2. Remove the camshaft, flywheel and crank- threads of the puller screw to protect the frontshaft, following the appropriate procedures, bearing or journal. Tighten the pulling nutPush the pistons to the top of the cylinders, against the thrust bearing and pulling plate to

3. Remove the camshaft rear bearing bore plug. remove the camshaft bearing. Be sure to hold r_r-Remove the camshaft bearings withthe tool a wrench on the end of the puller screw toshown. .. prevent it from turning, .

4. Select the proper size expanding collet .ands.. 6. To remove the front bearing, install',thepullerback-up nut and assemble on the expanding screw from the rear of the cylind_r,-block.

• THRUST EXPANDING DETAIL1,2 OR3BEARING MANDREL EXPANDIN( COLLET -!. •

• _'DETAIL BPULLING NUT ' " '_. //. "- DETAIL 1, 2 OR 3 "

" " tO__ __.0 BACK'UPNUT

)1 '1

PULLER SCREW /.;:_,:'.-' • ICAMSHAFT BEARING SETI ,.,

.._,_b.,_'::_.... ;. DETAIL 6 OR 7., [ TOOL-T65L-6250-A }.......T_,:_.. DETAIL 4 • PULLER SCREW - CAMSHAFT BE,_RING

-' PULLING PLATE EXTENSION (LOOSE) Ag045-ZA

Page 424: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" :_':'"_ :"" :_:_1_-45_:' "_'" . ' _ • .' '-. _ '.;:'_-BASIC._ENGINE_:_"._' .... . " . 1'45_' ,_. ,

.. ,,;REMOVAL.AND.INSTALLATION.(Continued)....

_.,,]_:l._::,-Installation,. • .. " [ ......... ' o intoplace:Be sure thefrontbearing,isin-,...:! ".-:,;"-'_._.i,-_!!_ii_._i:'.,;.;.l_'__}_",._:;l_',;_:_P,.dst on:ithe_-.ne_i:_bear,ings_'_at:tbe;_bearir_g::-':"_...:_., stalled:-,the..-,_specified;:distance;',below_the>,_,,_;--_;._"" " ":"" ': '_"_' _:"1_;'_'.;.... 'il_0_'e'_,-anclprb'ssthem"in"'Pi_zC__"it(i:'tl_b'_0L"' .' :front,face .0f.the.cylinder',bl0ck.' "

: __.;.. shown:Be sure to center.thepulling'plate:and....... :',:puller'screwto;avoiddamage'tothe bearing. "";_"2_!".?Install_the_camshaft:,rear_;beadng..bore'plug.

:- .., _ ,_,:_:_'_,:':,,:_;;.:_;_,i'_;_Failuretouse=,the,correct,expanding:cbllet__?._.,;_.:;3:_,:,ilnstai_tflecalmsL_afi;,crankshaft.fflywheel,and,._ ,::i :_..:..:_,. _,.i- ..........,.........can ,cause,,severe,bearing .damage..,Ahgn...... :_:._,.related.parts.,,,Do,,not;check_:.connectmg,rod,

• .'"::: :' ._":_.";,::.:_:.:_.the:oil.holes_.in:the'_bearingswiththe;oilholes':. - ;__::_c_.andi:main_bearing_iclearances._asa part of-._. :_":-',::-_._.,'-__._,-:_::_::;.:,.'Jn:tbe_:cylinderblockbefore:pressing_bearings,__"_.'_,:_:_._Camshaff_Bearing_!Repacement:"_;

. " ......:j. , ./.,,-./. ...... : ;'.'" .- ......

-- i...... '.,i'::,_ ::_,.l:._:,Piace:a!d'rip_pan;:unde[,,the:_oi/:filter._Unscrew. :,..... , ",,:,..the'filterfrom_the"cylinder block with_.a filter

.,wrench.

_ _:.: .-2: _Coatthe_gasketon'thefilter,withoil.@lacethe .....,,............,_._,,_.;- ' -__._.,;_-.,:,:..,..:::::filter'.,in:position:on;:the,tcylinder:block:,,Hand-

: ,..j:_:_.:.:':tightenthe_filteruntiLthe,gasket'contacts;the...... . , ,: ,_'

...........; ,er,. e,.ena0..oc ,t, ,orn,- _ ,. - : ?_'oil,_leaks.:lf;oil:JleakS.are_evident,-pefform:the

: _:-:.,_:•_;::_.;_necessary:',repairsto:,correct :the .,,leakage.- .... ,. i-. :.._.: .,. ...Check:.the:,oiL,level and _fill,.the crankcase if. i

._ .. necessary.- , . !

,. ::DISASSEMBLY AND ASSEMBL

When installing nuts or bolts that must be 8. Remove the crankcase ventilation regulator _ itorqued (refer to torque specifications), oil the valve from the valve rocker arm cover. Re-threads with light weight engine oil. Do not oil move the rocker arm cover.

threads that require oil-resistant or water- 9. Loosenthe rockerarm bolts,rotate the rockerresistantsealer. "armstoonesideandremovethe pushrodsin

ENGINEASSEMBLY sequence.Place the push rods in a rack so' . theycanbe installedinthesame locationfrom

Disassembly i_ _i_.i _i _ : .... ' _ which they were removed.1. Installthe-engine'on:aworkstand.;".." 10. Remove thevalve pushrod cover. Remove

the valve lifters in sequence to facilitatein-2. •.Disconnectthe sparkplugwiresat the spark stallationin the same sequence.

. plugs: Disconnect the distributor high tension'- :,o'lea_dat.the coit: Removethe distributor cap 11. Remove the water pump.

_ and spark plug wiresas anassembly. 12,,Remove the carburetor, .intake and exhaust3. Disconnectthe fuel line at the carburetor and manifold and cylinder head asan assembly.

:'fuel pump. Disconnect the vacuum line at the 13." Remove the crankshaft damper. Remove thedistributor and'carburetor. Remove the fuel cylinder front cover. Remove the crankshaftand vacuumlines. • front oil seal from the cylinder front cover.

4. Remove the fuel pump and discard the 14. Remove the flywheel.

gasket. 15. Remove the oil pan and oil pump and pickup5..Remove the oil pressure sending unit and the tube assembly. Discard the gaskets and

oil leveldipstick, seals.

6. Disconnectthe.distributorprimary wire at the 16.Check the:camshaftendplay; thetiminggear.: ' ;-......................... coil:..then...remove.the_distributor.,Removethe._. .....-': backlashandthe'timinggearrUnout!POsition

ignition coil and bracket assembly, the camshaft gear as shown and remove the "7. Remove the oil filter and oil filter mounting camshaft thrust plate screws. Remove the

adapter, camshaft, thrust plate and gear as anassembly.

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•• i ", , ';Y ?* i

'_.,.......... ;-..,....,:;._, .. ' ,r,";,_'BASIG_ENGINE_._:::i':!':.:;, :'":. • ' 1-46_'.-'_.',126: '_''":" ""'_'__......"

DISASSEMBLY AND ASSEMBLY(Continued)',,, ,_• . . .... • . .;_ ; :;_,-,_,,,. ._:: '....... _......... ......... . _..-,.:.,, . _,.:::...:

'._, I ' ', ..... " , _..... _" • '

. .-...17.i:,iRemove;the:.crankshaft.;gear_asi.shown:i::_..,,'.. _Asserfibly:'...i.,'_:. - ." ' , .'. "..""I, ,",-_.t'./,'!"18_'_;Remove_an_i"d e_,;and/or,=dep6_ts.",frdm:;ffh'd:?:;_._:':.:;_,_,:_,:tMan "of'_the_ r0cedure's_,'irene:here"arec6r_=".:.'.::'" ..i ."_-"".,,"_i_.:.:.;,':i.._

;; 1 . .:. ::upper_.eridofthe cylindei"bores. Remove the densed from other sections of this manual." I :' cylnder ridge with a r dge cutter Follow the • •-._ ". . , • ' 1 Clean andrespectall parts per theapproprate.... I ' instructionsfurnished by the tool manufactur- " nrnr,_rhlr,--_i=nrl__r(_.l_nintt _nM In_nC=r,finn "i!_..: / • er. Never cut into the r,no travel area m ...... '...- -.,"........ ._ / .-" .... _,, ,,_n -_A,,,,,, rl/,_o=,,,,_h_wh=,, ,-m,,,, excep[ oo not olsassembleme ol pump ano_. /:;i,.!,: _ ' .-',,-_?_............. _ ........ _ -"v '._ v,- hydraulic lifters for cleaning. .-.

/', " mg r!;ages.. If. ..... ,,X .... . , . _ 2. Remove the glaze from the cylinder bores by /",,.-" _" " lu MaKe,sureall oearlng caps _malnano con- . .......... ' :.',:" / '_.,: " .._, _......... fOllOWingme proceoures on page 1-14, Me- -'_"..... /_ ..... necdng roo) are marKeo so real mey can fini_hinn _lint-I=r W_ll_.'.'i - /::" :,_" • .... "" '"_ " _d _.':1 ' '_' "

, _,:_.: be in,tailed mtheir ongmal Iocatmns,Turn ............ ./ '." the cr&:nkshaftuntil the connecting rod being 3. Invert the engine on.the work stand. Position ' '

:i,';i" I : removed isdown. Remove the connectingrod new camshaft bearings in the cy,linder block, 'I. I, ,,cap . ........ • , , - -makingsure,thattheoil"holes'ir_iihe'bearing_::-..... _'::'_

:-l;_""_ii."20.1Pusheach.connectingI_<._. rod andpistonassem" ,are aligned:_',.with,those .in .,the'_block:,Press ....ili:?-;;,_i:'" I!-.i!_!;; • ,iblyout the top of the cylinder with.the handle . them in place. Be sure the camshaft front ".

, .!.i!i.... '_'_i:,.. _:end.of.a hammer.' Avoid. damage:.to-"the'" .bearing is installed the specifieddistance;. '_,;!!'_ -_ii!;. crankshaft journal or the cylinder wall below the front face of the cylinder block.._,,, . ."_, wheni_,mmovingthe piston and rod. 4. Install a newcamshaft rearbearing bore plug.:_:.. " ' 21. Rem01_;ethe bearing inserts from the(_onnect- 5. Oil the camshaft bearing journals and •apply

"'.... :ii ing r0_Sand caps. Install the rod caps on the PolyethyleneGrease DOA7-19584-Aorequiv-cohn_icting rods from which they were alent to all the lobes. Then carefully slide the

" _ _.!_ remo_,_ed, camshaft through the bearings.

_.:_ " 2_2.RemoVethe main bearing caps. Carefully lift 6. If the camshaft gear was removed, installthethecrankshaft out of the cylinder block so that spacer, thrust plate and gear, using the tool

':":'.... , the thrustbearing surfaces are not damaged, shown. Install the thrust plate,screws and . ,i"_._';'"; " Remd_ethe crankshaft.rear,.oil._seal,.,_Bandle torque to specifications.;'_'!" ',,.-.:; the crankshaft with careto avoid possible

..... fracture or damage to the finished 7. If the crankshaft mainbearing jburnals have _.been refinished toa definite undersize,install ';_surfaces, the correct undersize bearings. Be sure the

23. Remove the main bearing inserts from the bearing inserts and bearing boresare clean.

cylinder block and main bearing caps. 8. Place the upper main bearing inserts in posi-'24. Remove oil dipstick tube, the cylinder head tion in the bore with the tang fitting in the slot.'

dowel, pins and cylinder block drain plugs, provided.

25. Disassemble the pistons, piston r!n'gsi_and • 9. Install.the lower main bearing inserts in theconnecting rods, following the procedures bearing caps. "-'......under Pistons and Connecting Rods ....:.... 'Disassembly. 10. Carefully lower the crankshaft.in_iplace. Be .

careful not to damage the bearing26. If the camshaft gear is tobe removed from the "_.surfaces. -......

camshaft, press thecamshaft out of the gear _: ...... ' '' _- 11_.i_;Check,.the_,clearance_of_each'_main,beating's,"c .... _ '. ..... ::, ".. in an arbor press.. .. , _, _ . " "

• ;! following the procedure,g_ven,on page 1-19.i_._..27.Removethe thrustplate and.spacer. Remove' _.ii.._

• the camshaft.rear bearing bore plug. Remove 12. After the bearings havebeen "fitted,apply a,-._ the camshaft bearings. Refer to Camshaft light coat of engine oil to the journals and :•_i_ Bearing Replacement. ' bearings. Install all the bearing caps, except :.._

' the thrust bearing cap (No. 5 .bearing). Be _:'_28. Removethe carburetorfromthe intakemani- sure that the main bearing caps are In-- fold anddiscardthe gasket. Remove the in- '.stalled in their original locations. Torque

take and exhaust manifolds from the cylinder the bearing cap bolts to specifications. _'-headandseparatethe manifolds.Disassem-

,4. ble the cylinder head, removingthe rocker 13.. Install the thrustbearingcap and checkthe':_;i arms, valves, valve springs, coolant outlet crankshaftend play followingthe procedure'!_..elbow, etc..Place all parts in a rack oridentify, under Main Bearing Installation,page 1-39. -........

,,4_.-them so theycan be installed.,inthe same.,._... location from which they were removed.

Page 426: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" ....... " " " :BASIC;'ENGINE%" ,......" ": '"" ' ' ;_'•_i_47"'; ....,- .'..... ' .__ , ,, " . '- • 147" "

:. _, ,._j:.;.DISASSEMBLY_AND ASSEMBLY(Continued),....O:";'"_S"" ':: ....' i4' Checkthe"camshaft end la i camshaft ear .25.Apply oil-resistant sealer nthecavt es be-• .::" .... ,.... _..._'_:,..,...._'.,:-..._..:..b_cPJ'ash,.following;;the!.procedures_.on_page:.;_-.:,,.. tween.the beanngcap:and:cyhnder,,block...In-_. "

:"i:-i';:..,:-._:i:_.:_"._;i._i:_!!_;_._:_`:__`_1:-_7:_Jf_th_e_end:p_`_y_exceeds_:_specific_ti_ns_`_`_`:.`____stalha:new,seal_.in:the;!rear:main_.bearing:,cap_::...• . •i,. "_- •...replace :the thrust plate. If the.gear,backlash _,andapply a.bead of,.oil-resistant.sealerto the

..exceedsspecifications,_replacethe camshaft..-;- ,'.,:tapered ,ends_,0f._the...seal:o...... i....•_: - - !":gearian dcrankshaft,geari . .- ............... _.....26:'_.lnstall:new,sideogasketson..the.oilpanwith oil-

:i_i_.,.i;:.:_.15.'iCheck"the_camshaftgear, runout.witha' dial.: !_:_:_:_resistaht:seal_er.:Positilqn;a,ne,w,cylinder front -...':'":".,::_i,.',indicator._Jf'..the'gea'riruhout..is<e_<cessJve,re-i_'_.;.._-:,:::i'_.Cov_r_se._l:o_n:i_ii_ii!_pi_:_0d..!n_ta!!i.the"oilpan. ' _

....:. place the gears: , . : : .. .: ,, . :.. :._:27:.Coat;b_)th,si_esi'of.!a_._new::_wateiPum,p,gasket•::_..'_,_':.,36:,:::.Check;theepiston,to:cylinder_iboPefit:of-each :--:""_.','.:_<!,with":_wat_r;.re'sista_rlt,!'se'aler,_ianci;q_9sition"theo_--:-;._-:::_.:biston,fo Iowino.the oroceduie On o_oe,l-20'..::.,-.:.::_._.:;ga:_,'keti6"nit_ei_linaetibio:.ck_iC(_atit_ethreads.

:::*:':::.],/;--_neckme.end:gap;or :allpiston rnqs'on'paqe: ..:..: :,_,._._:,'.E,_.:--'::_:_,_.;,;7:÷:__"::,-:,,:,:_,;!;;E,_;;_,^, ,, , ^. . .^_ . ,, -- . .' . -- , ..... "-- . -- --..* .... .,'.,LI.I_j_W_d.L_I,._c_II.I,IU:3"_I_U,I;.I_,IUt:_:LI:I,_.'UUIt_ LU

• . ............ ,.,:, :,•.,_`_`_`_`:_:`_`_onnecting_ds`i_pwing_t._e_:`pr_c_ed_eun_-_`_-._`;_.`:._s_peclflcat!ons!:.,:..•_.•..,-..:....,:•.,;: _:.i:'.i-":. ", .:.....:.:' !.'-..::C_der.Pistons_.,a_nd_Connecting:,Rods_:Assembly_,_,s,:,_.28:Assemble;the_valves,,spdngs,".rocker,arms;,

-.:: .. " : '_-..: T'_,._.Check,the:pistoh.ring.side,clearance (page..-:" - ' coolant outlet elbow;_etc_._following the pro-. • " ' " .1_20). • - . _. ceduresunder,CylinderHead:lnstallthecylin--

der.head dowel•.pins....... ,.. :. ......... .. ..,'.....:,..18._'lnstall:thepiston_andconnecting,rodassem- . :.....,_.._,-.:_-,:_::_...--,_,.,,,._=_/.:.:.c_::.,_._:_,_..:_:,.,. ,._.._'.::,.'__...:blJes,and_check,theclearance-of..the_connect-:_:=,,_i29;:,'P,.laCe_a_,newJcylind_er_head_g,_sk_et:on.the

• ' -" :!__:_'_;:"..,:_,_-..:._J_.; ng_r,od.:bear rigs _._Refer _to/P ston and:...:. :.::_.'_.bo'ck.!.!iCa_efulJyil_OS-tion.ithe.'_yr_cl_r,bead on".:. : _:.:._°':-',Connectmg:Rod Installabon.'and_Connectng-'.;::_-__': the block_.andnstall_the,bots;:_orquethe bolts

..: ." .;,:',:- _::,_Rod.Bearing"Replacement....... :_. • ":: -.:..:,.in,:seque_(,_i9iiS_)_e_ifi5atibr_s:,_,_Nhencylinder

,." ._.., ::- _"::,::.::19...,Coat"a. new.;.crankshaft..:front:.oil,;seal_,with ..-.-: ::head_boit_'_,l_av_!:.beeri?..tigh_teH_d_:it-iisrnotnec-..... - .- "_-'-,._.:,essa.ry:-t0.ret0rqu_'-,_the'_ibolts_after.,_extended-. , . .:., - ,"-.:-,'::arease'and4nstallit n,the:cyhnder'.frontcover. .... "'" - i .,, ,..., ,:, ,. ' -• ' ' ":'_ ' . . .... . ' , ..... -'.,- :-::.,:.._.operat_o:n.:_:_ow:ev.er._-'_[.ne_DOl_S_,may-..De..

.:L......:._..'.:_c:::..20.-.COat:the:gasket_surfaceS_of_the,cylinde_:f'r'ont:.."-.:.i_;:_che:c..k.eld!and_[e-!g_qeed:!if:ide_ired:'" - ,". ,;_7:..'_",_:,..,Cover_rand_cylinder.:.block,_with_:0il._resistant.,L:,_:_3d_:,,Clean_;tb'e:exterior_sorfade_:df,;the;_ialYe_lifters.._.

". -..._ _. : .... , ;: - " , ,L • -_ :'_'-." :" '__'._"-::,-_-". ' ""-_; 7_''_': _ "_'_' " "'" ":.:_:',;_,.; .._,;.........;seaer._Post on.the :gasket:on_.theb ock and _, -__.,.,.;wth'a,c ean,'hnt-free,c oth and,o the.surface . •...... '.... .-. ;install.-t.he:;cover. _orque _the. bolts to .... with engine oil:lnstallthe'valve_lifters in the

specifications... samesequence that they were removed.

21. Lubricate the damper end of the crankshaft 31. Apply polyethylenegrease to both endsof thewith a white lead and oil mixture. Apply Poly- push rods and to the push rod bores in theethylene Grease DOA7-19584-Aor equivalent cylinder head., Install the push rods in theto the sealsurface of the front oil •seal.Apply ,. same sequence that they were removed. BePolyethylene Grease DOA7-19584-Aor equiv- sure the push rods are properly seated in thealent to the seal surface of the crankshaft valve lifters. Engage the rocker arms with the

.... damper and install..thecrankshaftdamper. •push rods and tighten the bolts.

22. Apply alight_film:of:engine_•oil_onanew_crank- 32:.Adjust the valve clearance as described onshaft rear:oihseal_...Apply_P.olyethyleheGrease ' page 1-23, - "_

, DOA7-19584:Aor equivalentto the seal con-,.. tact .surface of the crankshaft and install the 33. Coat the gasket surfaceof the push rod cover

• , .... .sea!.:the.specifieddistance below the face of" with oil-resistantsealer andposition a new•the cylinder block. Be sure the seal was not gasket on the cover. Install the cover and

' " damaged during installation. .gasket on thecylinder block.Torque the coverbolts in sequence to specifications.

23. Position the 'engine rear cover plate on the 34. Install the carburetor, intake and exhaustrear of the cylinder block and. install the.flywheel on the.crankshaft. Apply oil_' manifold, followingthe-procedure under In-:

,,, resistant sealer"to_the threads of the fly- takeand Exhaust Manifold Installation. ,wheel attaching bolts. Install the bolts and 35. Installa new gasket withoil-resistantsealer

• torque them to specifications., onthevalve rockerarmcover. Installthecov-

24. Use a newgasketandinstallthe inlettubeand er onthe cylinderhead and torquethe cover• • screenon theoilpump. Primetheoilpumpby screws in sequenceto specifications.Install

fillingthe inletopeningwithoiland rotatethe the crankcaseventilationregulatorvalve in.pump.shaft until .oil,emerges from theoutlet the rocker arm cover.• . ,_

' opening. P0si(ion a new"gasket 'on the oil ' 36:InStall the'cylinder' block_drain_plugs'&nd'"oilpump body and install the oil pump and inlet pressure sending unit. Install the oil level dip-tube assembly. Torque the attaching bolts to stick tube and dipstick fill crankcase.specifications.

Page 427: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, ,, , ,_;, ,, _. _.... , , . , l ....... , . , ' _';" .,;,,"., _: ', ,' • . '1" ....

DISASSEMBLY AND ASSEMBLY (Continued):

,: 37_:;Ir_stallthe0!Lfiltermountingadapter.-Coat.the 40..,Usea_newgasket andfinstall'theffuelpump:_:_.,,' ,It': : .: ":'_/:_:_`_sea_s(Jrface`_f_a:ne_`_i_:fi_ter_!w_!th_grease`_(_r;_::_`_`.;_::_``_`;_:``_:Torque<tl_ebolts,_t0:specf cat ons_;:lnstalll,the'_;i_;,_,' _ ' _". :,,l_:.'.:"-'::?.i':'_ie6gir_e_::bil):_1nst`a_:_t5`6_i_`_i_ter_unti_t_e:;_sea_:!_r:_:_`i_:carburet_r`_fu_e_:_in_et_inb'_nd:distribu'tdi"_Vat-";" ..... -, .,, ,.-_ ',.: h..I __: surface contacts thecylinder block, then tight- uum line.I , en the filter an additional 1/2 turn ,, . ........I ' " ,_]. ms,all the oistriou_orcap ano sparkplug wiresI i. 38. Install the ignition coil and bracket, assembly.Connect the spark plugwires. Con- . _!I..::'i:,, 39. Position No. 1,cylinderonTDC after,thecorn- nect the .distributor primary and secondary ..Ii i_ pression stroke. Install distributor with rotor high tension w_resto the _gn_honcod. ::[i:':i_ poin{i_g at number one terminal in cap, and 42..Remove the engine from the work stand : •.::_I:' i_ arm_,ure and stator assembly polesaligned. _ _:

I.::. Inst_l:llhold-down clamp. ;

y,'

:':;_!':CYLINDER_HEAO '-_,::.:_..

,E s-651,:_i',;.Disassembly,•

1. Remoye the coolant outlet housing and ther- ROT*,OR _.......- mostat, Discard the gasket. 65,,"'__ _'_ ,/6_ETA'NER

• _ _"_ ': '_¢".:!.. 2. Remove the intake manifold, exhaust mani- _ .

"_T' fold _nd carburetor as an assembly from the VALVE ,_'_.,%, _ VALVE' cy_Inderhead. Discard the gasket. SPR,NG_._

', 3. Remove the spark plugs. :_.,_4. Remove the deposits from the combustion _

chambers andvalve heads with a scraper and

' a wir_:brushbefore removing the valves. Be O,LSEAL.-6571."'_t _ _OIL SEP'L-6571 '( "i.i.. carefi_l not to scratch'?the"cylinder_head _,__,_" gasket surface.

5. Compressthevalve springs,thenremovethe EXHAUST ,NTA_Evalve spring retainer locks and release the VALVE VALVE

6505 6507

6. Removethe spring retainer, spring, stem sealandValve.Discardthe valve stemseals.Iden- _tifyallvalveparts.

A2432.1E

VALVE SPRING COMPRESSOR '_" " "

Assembly :_:_-:.:.1.. Lubricate the valve guides and _,a,lve stems

.: with heavy engine oil. Apply polyethylene_::_!,_grease t0::the'tip-ofthevalve:_stems:_-:.',,-:.: : _ ., :..:,. "' ,_:_'

2.,/ Install each valve in the valve guide fromwhich it was removed or to which it was fitted.

3. Oil and install a new intake valve oil seal onthe valves. ..:.

• " 4. Installthevalve springoverthe valve.Be:surethe closed coil end is placed against thecylinder head.

5. Position the spring retainer on all valvesprings.Make sure that a positiverotatingretainer is used on all of the exhaust valves. _.

6. Compress thespring. Install the retainer !,A2855-1C

' ' locks.

Page 428: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• '_";" ' :7_"'f1_i,9_" ' ,_ ' BASIC'ENGINE_:_ ':. ' - ,. 1_9 _":. ( ,

• DISASSEMBL¥,AND,ASSEMBLY.(Continued)..:.....

:_"_ = •. ": ;ii i.-, :7: %Measurel.the::assembled;height:of,,_the_valve_;,::.- 9,: Using_a:"new, gaskeL;coated_,with;:.water_.._,

-'. , "; - _..,,._..,,springpad to the'UnderSide'0f:the,spfing_re- ' :. ; =:coolant outlet elbow. T0_;quethe attaching,_.: .........tainer.with.dividers, , _ _.::!bo!ts:_tQ,i.specificatior_s.,.. .,,,. :,.,:.

,,, .-- ,: ....:;.,,.-, ,Check.'the_dividers_against.ascale.,.If:,theas--, .... .• ,.'.: '_:_*UNDERSI[_E; _OF': SPRING' RETAINER .. •

: !; .: ':.: C :_",'.%.'..sembled_.height,isgreater thanthe specified limit ..: , _' i ' " "....• , , ::,;,:__ i..!_L_Jnstall,_.the-necessary_0.030:,inch_thick'spacer(s):-_.'.?:_.'_; ", ',_,... .... . .;-.._,i_.!,_be_een..the, •cylinder hffad ispring ,pad.and the ';.' ":,i::_'."'-' ..,' ' ,,...:;:..':: ..::. 4- :;..::walye'spring,:ito:bring,the.assembled:_heightto the; ._-- - .-,'_-

• . .% .

•i :-'-,..: "?:,:: '-.:_;,',."_',,,:recommended;dimension'.Do'not' instal[_spac, ," .,_- _ "-" " _ :.i,.,:;:.,,sers:_,unless_necessary._use'of_spacers.in .ex-li.' _, !:.::!:."_.... .

t::_::-._cess:,Of,-recommendat'ions',:will_'result" in-'-.• _-.,.._.,,,,:_;,:,:_,:-,;'_.,_o_overstressing_the=,,val,vespdngs.and,overload- ;..:

v ,'. _.._`_;_:::`:_i_`_isp_ng;br`eakage_iand_`w_r_n`_camshaft_bes_:::_!:_:`_._:: ' .....• , . .. . . :

• '.. ' 'i!' .," _:8."-:_ositionanewJntake manif01d:gasketonthe" -., -:",:cylinderhead.lnstall theqntake manifold;,ex- ",

..... .. -' .' :-_,. ,J'_",,_.':::haust manifold'andcarburetor:as,an_assem......-.',. ' .::. :?bly_-".Torquelhe_manifold_bolts:.andnuts in ............ _'_'_;;_':'_::_'_t_SUREAGE:':0F_'SI_RING_pA'O¢>_'_':":_'A2857"A

' ' ..... :._: sequence.to!specifications. " ' ., - ;.:v_'/;'-;';-•i'.;.•:_:;;_.;<.::;':",'.-';: :•:. :L';,".,

, - ....VAIJVELIFrER ..... :,,. :,_ :,.-_.v.._:., ,...... . _..: •

" .. ?Disassembly . : POS.ROO'CU,"'

, :_'_:',,.:::Each,valvelifter_is_a,matchedassembly. Ifthei :_ _ ' ,:: _;'_M.ET,ERIN,G,V_L:V:E_OISC ,_. _.; :_ ;., ....... t:; ; ;. . "

. ., .<., t.-.:,.:parts,:of:_one:lifter,,are_i:intermixed:with.;thoseof; . ..,r;..;_.,::_...... ,.:.,.,,_:,.,,,,,_.,.,..,_....._:_,..._._ ............. ,- .,-., ,...:,:..another;improper.valve•operationmayresult.Dis- (//_ /=", CHECK,VALVE" ",/ .

• " _:".,_.:: "

assemble.and assemble-each.lifter, separately. _ 1 /PLUNKeep the lifter assemblies in propersequenceso.that they can be installed in their original bores. GE,SPR,NG

, aso,.eoc.rn.wt.neeOenos oersto/LOCK RING '_i.:.. _ 1 "release it from the groove. It may be neces- :sary to depress the plunger to fully release thelock ring.

PLUNGER / ":

2. Removethe push .-.rod.cup,.,metering valve(disc), plunger and .spring.- CHECKVALVERETAINER

3. Invert the'plunger:assembly;:andremove the, ' ,check valve retainerby carefully prying up on

A2867-1Cit with ascrewdriver.Removethecheckvalve,

' _i g_ ,' :, (disc:or:ba!!check),andSpring.

• For.the cleaning and ,inspectionprocedures, .-- : '

referto page 1-11. 4.' Placethe plungerspringand then theplungerAssembly (open end up) intothe lifter body.

Hydraulic valve lifter assembly is shown. ', 5. Positionthe meteringvalve (disc) in the plung-er and then place'the push rod seat in the

' ........ 1.• • Place the plunger upside down on a clean plunger.work bench. 6. Depress the plunger and position the closed

2. Place the check valve (disc or ball check) in • end of the lock ring in the groove of the lifterposition over the oil hole on the bottom of the body. With the plunger still depressed, posi-plunger. Set the check valve springon top of tion the open ends of the lock ring in thethe check valve (disc or ball check), groove. Release the plunger,andLthende-,"

" :" 3/ 'Position the check valve-retainer' '0verthe _''......_,,,-Jpressit,again.lo:fully_._seai:.the.,,.ock,_dng_:_.:. _i icheck valve and spring and push the retainer 7. Use the hydraulic valve lifter leakdown tester.down into place on the plunger, to fill the lifters with test fluid.

Page 429: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•DISASSEMBLY AND ASSEMBLY (Continued)

• :OIIL:PUMP-,,, :, " .,.,_ .... ' . : " '• • "',,, PISTON,AND:CONNECTINGI_ROD::;:::_;':; • _

_" .i:,!:OJsasse_llbiy ,r_,_'•_',:.•> ' ".i, ' " ........ Disesse I .... : ' " ' : ....:""

".'Jill,1.Remov__the cover attachingscrews and re- 1. Removethebearinginsertsfromtheconnect-_: move ti_'ecover, ing rodand cap. _. :

Remove,the inner rotor and shaft assembly, 2. Mark the pistonsand pinsto assureassembly .- _ !i then re_ove the outerrace. _:_,';_ with the same rod and installation in the same ..

":'i 3. Scrape_way the staking marks on.the body :-_.,:_; aroundi_theoil pressure relief valve cap. Drill a 3. Remove the piston rings. Using an arbor ,- _:._ " _-:

i",;.i:. 3.175rn_ (1/8-inch)hole in the relief valve cap press and the tool shown press the piston pin ....:..:_, .i_ and insert a self-threading sheet metal screw from the piston and connecting rod. .

i.,_. ofproper diameter into the cap. Pull the cap _!'_,i:!_i, ":'i: out of :tt_'e.chamber Remove•the spr ng and Refer to page 1-13for the clea rigand inspec-

-_t_:,_!!!iI i.i,i,;i!i_i_,-,,plunger?.._. ' ", ........ " . • tionand repair proceduresS': .,,_._;i-::;,,_ . - .T.!:. Refer to page 1-il for the •cleaningand inspec....

' ,:_!;;_. ;'i!:!!it0n:and,.,,,., •repair.procedures. ,,

/';_% PRESS RAM80DY',(PUMP ASSEMBLY-6600) SCR EW-20346-S

/WAS.ER-S.0.-S..\:,_/t. IOEN_I'PICATIONI _ 1, _ "

.,. / ,PR,NO:,,o -_ OR.VER

,_' _ ROTOR AND SHAFTASSEMBLY-6608 "(" " .

COVER-6616 "_-_

_/LOCKWASHER-34805.S

SCREW-20324.S A2165-BINSERT TAPERED PILOT

• _ -- IN PISTON PIN FOR

Assembly. R_VERS'_LEPIN REMOVAL

LOCATOR T _ INSERT THIS END1. Cleanall partsthoroughly.InstalltheoiLpres- _ IN PISTON HOLE

sure reliefvalve plunger,springandnew;cap, i_]_-_,.._.. FOR:_,:.<.INSTALLATION•S,a e,hoca0in,o s,,on..... --\_ADAPTER,2. Installthe outerrace (recesseddot facingout

on same side as dot on rotor) and the inner _ ..... _:'__

rotor and shaft assembly, cu_;_' ' , . '" " PISTONPIN_'.,_, .

','TheInner rotor and shaft and the outer race ,:/.,__ REMOVER/INSTALLER :_ ' :

.:m;e._serviced as an assembly. One part should ,_not be replacedwithoutreplacingthe other.

..3:, Install the cover and torque the attaching

;!_.screwsto _,_tion_. _:_

Page 430: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

+ CYLINDER+ASSEMBLY ORBLOCK Assembly

Disassembly, 1, Cleanthe gasketandsealsurfacesof allser-viceableparts and assemblies.

1. Mount the old engine in a work stand andcompletelydisassembleit, removingthe cylin-_-.' 2._ Positionthe new cylinder assembly,block in • _der head and manifolds as an assembly. Fol- the work,stand and transfer all serviceablelow the procedures given in the Removal and parts removed from the old cylinder engine,Installation Section of this Part. following the instructions given in the Re-

moval and Installation Section of this Part.2. Remove all serviceable,parts not furnished+

with the new cylinder assembly or block, in- 3. Install the cylinder head locating dowels andcluding the cylinder blockdrain plugs andcyl- block drain+plugs.inder head locating dowels. 4. Check all assembly clearances andcorrect as ••

.....necessary.

Page 431: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

Thesolidstateignitionisthe Duraspark II break- RPM. The movement of the centrifugal wezghtserless type. It is equipped with a vacuum and change the initial relationship of the armature tocentrifugal advance to control ignition timing, the stator assembly by rotating the sleeve and

The distributor provides a signal to the ignition plate assembly ahead of its static position on themodulewhich controls the timing of the spark at distributor shaft. This results in spark advance.

,, thespark plugs: The. signaLis generated,as the The rateof movementof the centrifugalweights isarmature,attached,tothedistributor,shaft:,rotates., ' .contro ed by calibrated springs.past the stator.assembly:_,The'rotating armature_ Thevacuum spark control mechanismprovidescauses fluctuations'in amagnetic field prOduced spark advance. The diaphragm assembly alsoby the stator assembly magnet. These fluctua- varies the.armature to stator relationship to pro,

.. i ::,tionsinducea voltagein the statorassembly pick- videsparkadvance. Inthiscasethe statorassem-• ..; up' coil.: This signal is connected to ;the ignition bly position is changed by-means of vacuum

module by the wiring harness, applied to the diaphragm assembly. Vacuum ap-The occurrence of the signal to the ignition mod- plied to the diaphragm assembly causes the di-

ule, in relation to initial spark timing,:is controlled " aphragm and attached diaPhragm rod to move,by centrifugalandvacuum mechanisms. The cen- compressing the advance spring, which controlstrifugal advance mechanism controls spark timing the rate of spark advance. This movement of thein response to the engine RPM. The vacuum diaphragm rod, which is attached to the statormechanism controls spark timing in response to assembly, causes the stator assembly to moveengine load. with respect to the armature. This changes the

initial armature to stator assembly relationship es-The centrifugal advance mechanism varies the tablished during initial timing set, causing spark

relationship of the armature to the stator assem- advance. The stator assembly is mounted on thebly. The sleeveand plate assembly, on which the lowerplate assembly which,-alongwith the di- "

.,.,,..,_ ......armature,,,is'=_mounted;-rotates,in"relation_to"the, aphragm.assembly?is'attached |othei:liStribUtdrdistributor shaft. This rotation is caused by cen- base.trifugal weights moving in response to engine

Page 432: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

_" ' __ __ _t • _ . , *.. , ....... . ............ II " _:.:_" _ ; " '";" '_' ,"" -'

•DESCRIPTION (Continued) __ _....

, . , . • ..

"i '.. _', .' . _R3L . , ,BALLAST', ' ' " .,* . • .... :_•'::RESISTOR "', . . '. ' " '*"_ ' ' ' "• ' " 'RUN - " *

D'Sl"RiBUTOR ' :'

" '_ IGNITION SWITCH ' START _ ....

BYPASS

OR ' !;,' _., • ..: ,i_,

"-"" ADAPTER

SPARK PLUG

_"_" ' , "" ; i ST_RTER'RELAY • " i ' '"

=_:_ DISTRIBUTOR

BATTERY

':_:, The Duraspark II ignition module is shown. The response, to a control signal. In the Duraspark I1• " standard base part number for this module is ignition system this control signal comes from the _,

12A199. distributor stator assembly.

The ignition module performs the function of,,.turningoff current flow through the ignition coil in

OURASPARK IIIGNITION MODULE

12A199

VACUUM A_ II_ -

] STATOR ' _ i ......... _/'''_"

JASSEMBLY " _ '' tI ,*' '

; I I

_ _ ._....-- J-'__/ I_ ',ARMATURE

• BLUE GROMMET-DURASPARK IIDISTRIBUTOR HOUSING CENTRIFUGAL ADVANCE ....

B4082-2CB4187-1A

Page 433: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

..... :........DESCRIPTION.(Continued),._,.5-, 'q

. ,_...... .,:"Z_ffhe._Duraspark_llignitionLsystem_,consists_ofa._::._•,...Thesecondarycircuitconsists_0f:the:,i.....• ._.j,,:,., .i:_i_;:_;,_t_'_primarY_and_a'_:secondary_circuit__,.:.i_.:, ,. , ....

, ". " . -Theprimary circuitconsistsof the: .." . ... :.L:,2.._dgnition_iCoiltSecondary,.:Windirig..' "I.. Battery ....... -":_"._.......," ::: -..............'...........' • 3... Distributor.Rotor ' - "

.. .,'--:i2:_;,Ignition:Swjich..... .,- . . .4:-,Distfibutor_Oap_.. :" . '? :.i: ....... .

:.y 3: _Ballast.-Resisto[:---_Starl.Bypass(Wire . 5..:Ignition •.Wires...... ,.-' %4.-:Ignition_CoilPrimarY,,Wind!ng

• .. .-.. _ .. • . ..... : " ...6..Ignition_Switch '

• " ,. ,, 5. i, Ignition:Module ,, .... ,.,":.:'-,,_7÷<.BailastiResistort_._St_'rt:_B_]pass_i(,Wires)

- • :6. DistfibutorStatot Assembly .8.. Spark'_Plugs ....

IGNIT'ONSW,TCH_ S .... .

_._.. ...........BAL._ASTRES,STORJ

. :'BATTERY _- /

• . IGNITION WIRES " " : . ...,: .' " ' '-'_ | <:< ,| . . ,

. _ !.iii::'. _.''i'i'_.'_<_<',''ED'_'.I ""_'. TI.''.. ' -.... " " '_ <i '_-"° o :OIL............... "' ""_"_"?|oRE_"'__'I.',O.,_,.ON.MODUL__ "_'-_"""_'"........

___A---_ -_" ' STATO"ASS_MB'Y _!<< !O.ANGE, ,PUR..E "I _ . I BLACK

. ,"_ DISTRIBUTOR IGNITION SYSTEM GROUND

SPARK PLUGS

B4Q84-2A

Page 434: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,._;_,._._,2_-04;:,.:..,'_, ,, :_,,. ,_.•::',,.":"_..".....: '" ,:':,!_;:_,'_,'-:;'!/_,;,.:IGNITION_'SYSTEM!I:iI:_'_?':{."_",,, ' 2:04_"•: "

DESCRIPTION (Continued) . _ADJUSTMENTS.,_.. ,.,_ ........ .,

• I .....With_the:'ignition,,,switch,i_i.the,,Run:,position.,......... Ignitionsystem_adjustments:arelimited_,to:initial-:i,,._.........;,-i)pr,mary,::cir,cuit:current,f, lo_Nsffr,om!ithe_batteFy;,_.;:/ ;i. timin'g. and,.:spark.,.plug_.i:gap_on:_DuraspaFk._ll,{' _,''.: , _ _ _,_

.,_!_:::.Ji;.,,_thrddg'h,ihe_ignition,switch_.th.e:ball_st_.resist.dr,;_tli'e_'iL_ ?_,systems:,_-.,_..,, , ..... ,. .,, • • .... , ,._, :. 'i.,:iJ,;.,;_!ignitioncoil primary (BATTERY), the ignition mod-I_ ule (GREEN/wire).and back to the battery through INITIAL IGNITION TIMINGJ,'the ignition system ground in the distributor _:I,'/(BLACK wire). This current flow causes amagnet- The timing marks and their locations are illus- :/_ ':"'

, /;"i,_iCfieid to beLbuiltup in the.ignition coibWhen the trated on page 2-18.:!poleson th6i_armatureand stator assembly align, For checking and adjusting the ignition.timing .ii :_:._.:_!.theignition_i_oduleturns theprimary current off, with a scope refer to the scope manufacturer's ..'f_.... ._-i__'.icollapsing i_e magnetic field in the ignition coil. instructions. To check and adjust the timing with a

_!_Thecollap_i,_bfield induces a high voltage in the timing light, proceed as follows:

:!i : _:ignitioncoilC:_econdarywinding. The ignition coilI"!:wire condu_t'Sthe high voltage to the distributor 1. Clean and markthe specified_.timingmarkwith

i/iii!where;the:ca_p and_,rotocdistribute,it_to,theappro-,,:',,, chalk ,or..white,paint.: .... . ,..._;:,_.._.,,,.._,,._"_'priate_sparkplug__..... . 2. Disconnect the vacuum.line,,'a;fidplug thedis,.

!:_. A timingcircuit in theignition module turns the , connected,vacuum line.:i:i:primary_currentback_on_"after,_ashort'periodof., 3. Connecta timinglight to the No. 1 cylinder

i.Jiitime.HighV61tageis produced each time the mag- spark plug wire. Connect a tachometer to the,,.,i:neticfield is_built up and collapsed, engine.

The RED'ignition module wire provides operat- 4. Start the engine and reduce the idle speed to,:_ing voltagei,_for the ignition module's electronic 600 RPM to be sure that the centrifugal ad-

,component_i,.inRun mode..The WHITE wire pro- vance is not operating...rides voltage for the ignition module during Start

mode. Bypass provides increased voltage for the 5. Direct the timing on the timing marks. The light,;ignition coil during Start mode. should flash just as the notch on the pulley.... lines up between the 4 and 8. Check specifi-" ,J_ cations for correct initial ignition timing.

,,,..ASSEMblY"'_ 6. If the timing is not to specification, loosen the- distributorretainingboltandrotatethedistrib-

. utorbodyuntilthe marksarein line.

Ignition timing is advanced by counter-A'_G_M_TO_' clockwise rotation of the distributor body,_,_MAT_EA_ while clockwise rotation retards timing.-- STATORASSEMBLY"

PO,EB 7. Tighten distributor retaining bolt and connectr vacuum hose.

C" .",_ 8. To determineif the advancejmechanism is--A_ATU_E functioning, accelerate the,.:engine •while

watching the timing mark with_thetiming light.The notch on the crankshaff":pulley shouldadvance as engine RPM increases.,

!

B3509-!B };_:9. Disconnect,the_:timinglight:,_,.',_..... ; ., : .- --

% O,A NOS,S,NO,,S,,NO';_i:_"K_ Proceduresfor ignitionsystemdiagnosisandtesting are shown in the tests o n the fo!!owing .pages.

B4283-1B

Page 435: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'- _, ;_2..05_ _,i , . .... ". ..... .,, _r."_IGNITION_SYSTEM:_:'";_';:'_....... 2"05"

,._ .,_:,.DIAGNOSlS,.ANDTESTING.(Continued)

-...i::_.' !_:., e Visuallyinspeci'thei_ngine compartment toen-" e" Digital:V01t-orimmeter:Rotuhda_014:00407::,__.... ,._:',r,';:sure,'allvacuumhoses"andsparkplugwires are i' "'::,,-,'e,Small :straight_,pins_(,2)::- - '. :_-:,_

• ,. ;'properly routed, and_securelyconnected.

...... ._ "_,',:_, .:_J:_Examine,all;,wiring harnesses,.and:connectors _ • _'Notes. ....• ; -'_,'for insulation damage burned._overheated _ , .... .- .. :,'- " ", • "" "": ," . , ,, ", ,. • . - .,. ..,... :.,,',-,.:. :e..All wire,colors referred_tom;thisDa.d relate to the-., ,,i - " ;__ oose;"or broken 'cone zons " . . : '.. • _,. _ • _ ... _ ..... ,,,

• :. .... . " . . . " • , '. .". ..... ,.,,, ,._.:.-.:,,_.,_"colors!o,f_tbe_ignition_modUle!Wire's,;Whenwork- -'.'.. - '.........._.:_,-_._e_::_Be;certain:.,the,battery::isffully_charged_=;-_, --:. ,.-r:_.,_ _._,:ng.,,.Withii?:a_wiri_g:_harness.,_tl_e,_;Wiies',_must,be

: , _ " _ • _ .'. .- • '. .... .,., ,,o,-:: ..... ,-.',"trace_:!b_cki_tS',:-the':",i'_ _ibni_m0du_(f0r_ ro er"_' ",'"."".:, ._,_',:_e;.,AIl'accessonesshouldbe:_Off:durmad_agnos_s.' ::. ...... ,..::r.-:._,.../-.-:_'..,.,..'..:,g,_,.,-.-'_'-........ .:_-:,.,: p p• ,. - : " . " ::_:COlOr;,ioenzlr!cazlon:_. . - - i",.,_:-'''

-, ..... % -

-, _,., Equipment . ..::o:.._-_:......_ :.:......,-...;_.,..._..._.;r..-._,_-._.::_;.:e..,,When,_inst_(icte'd;_,tO_inspect,_a!_.wir,i_g_.harness,' • ...... . ,. "........ ....__..... .,.,,both:-a Visual:.inspection _;and._a_c0ntinuity. test

_ ': , ,-, ,:/' ..":./zObtai n_"the'ffoll0wing'_test_equ iPm ent_'i'0 ,...::',_:".should, be::performed..r_an! ..... = - ,. .

_- equivalent: . -... - - • When making measurements on, a wiring har-.. ... -. L:"\e_,.Spark_ester;,Special •Service TooI"D81P-. " -..ness:orconnector,.it is good practice to wiggle-

-,6666-A. .. _.- . .the.,,wires.while:measuring.... ..... ,_.._,,

_, ,: .... ;.,":TEST.STEP ,' ...":,_7_RESUILT.. -.: ': _-'.;._I_.ACTIONTOTAKE

I "1 :?START'CIRCUIT .. ..... ,."'-;. ' ". " '

_. -::.... ::::e:_Connect'spark,tester:between.ignJtion coilwire_and-- ..'Sparks.. _ ." .'.. _:GOtO2... iengine.ground.. ........... ....... , .... .,

.... _ • _.:""_,2e.:_Crank_engine,using_ignition,switch.. ,..-:, :., :No_Sparks ' _ .." :":.._!_,._._;i_ i_;ME._SURE,resistance_of,"-. ignition coil wire.

TO IGNITION COIL Replace if greater,than

" 5,000ohmsperinch.

INSPECT ignition coil fordamage, carbon

I tracking.

•CRANK engine to verifydistributor rotation.

. SPARK

.... IBIII_IB_ ,- TESTER'. GO to 5.

1..,-'="ENGINE

GROUND _,A6025-C

Page 436: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

DIAGNOSISAND TESTING (Continued), :,_:,_:.,_. :

, I ....TEST. STEP "1 _..,RESU!-T....• : . 'ACTION_TOTAKEI:.' '_!:_"_,i'- " "'" : 2" " "_RUN',CIRCUIT,,," - • - ' , "," . '"

i ' " .... " ....... " ::.'_.,_::,"-,;,,.':' -.... ': ..... "_.,. " '.' ':'". "''

[_,:_-: ' <'_ • Tum.ignition switch from Off to Run to Off position Sparks INSPECT distributor cap,

:'i,. .Ii: several times, adapter, rotor for cracks,

!_: .;_i1'_ • Sp&i_kshould occur each._timeswitch.goes from Run carbon tracking, lack of _.. ._-_

_'_i,_.._:"i;'/!!:1: .to ..-_Off_._position. _ • .......' i,, siliconeCHECKcompound.for ' _ ' _:_rolLpin"::1_i • Remove spark tester, reconnect 'coil wire to

'_ :1" distiibutor cap. securing armature to ii'i ':.,i.I_.i_. I _ . !_ sleeve in distributor. _:, //_.

? " _. ! _i_': CHECK that ORANGE ..and PURPLE wires are

"i"" iI'II! COAT COMPLETE SURFACE OF not crossed between

;. ROTOR BLADE.TIP.WITH distributor, and ignition'i, ' ": "_'' "SII"ICONE'COMPOUNOI-- :1'I32_'THICK " " module_?_

"' _" No Sparks GO to 3.

NO COMPOUNO ON

THIS SURFACE 6- AND 8-CYLINDERESCORT/LYNX. APPLICABLE TO 4

,',' EXP/LN7 CYLINDER

'" ' I *DO NOT USE SILICONE COMPOUND I A6027-B

[ ON MULTIPOINT ROTOR. I

Page 437: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• _..DIAGNOSISAND .TESTING (Continued).

"°, .'s_t';'_"_'_ " - -' "., TEST STEP - ;. .... ' RESULT ..{ •ACTIONTO,TAKE

p_

_'!"" _"°k_'':"q'''_ i : ' .....•., , ..:.- --.,t...,.__.3,';;,I,_MODULE,:'_.VOETAGEv,,._,:_ .-, ..

. '.. . :, "-: . '"-e',Turnighition switchOff. • ....... : "} 90 peicent"Of.batteryq• '-!.'!'{.:.;GO_'to;'4. ' "• votage:"or'greater .. " '

.- '. .. ....... :, .-...l:CarefuUy,'insert.small:straight'pin,inRED.,module ..... "." .: _." ..... ... '.. . _- . -

' ' "" ' l _" r " " '.... ' " ' " '_:'''_ '':''1kess,thah;90 i_rcentbf; _'•'?l_;Ref_er.'_to{wiringdiagl'am, i._ .,.. ;-:., ..,;_'-,_i;.::_.;_:._CAUTION:,Do,not:allow,,straight pin to contact _..rI._,batterv'tvoltacle'",f. -,,,_: ,_'_ol,_lnspectWiringharness.'.... : ...:-:_ .-,:electrical:ground. .... . .. ' " "" ...... J .;:;__' "_' i:_-":-._:}i,.:i!,_ii,Ji_between;moduleand_:'

' ' ". :. - ',_ ' ' • " " .. : . " • : I ' : :_ '"':". ::°" _"_:_"":-._'.'._ignitioni,switch."-'.... '_ ' '.'; ...":.',..2,.-'Attach:negative; (,--'_.')_VOM:lead:to distributor base;- . -. " " .... _-' *_''

__..<U=asure..ha,er,swo,a,_e.` . • ' ...:._ , -_k_.tWom;or:damaged• _ , • '. " ...... - :"......,."'-_;Jgnition;;switch./

.. - ' . k.4:_Measure._voltageat,straight,pin.with ignition-,switch.,...... ._in.Run,position.,._Y.T:(-w._:-'.." .- -..- , . __:.

... - rL ..... : ,,C5::::Tum:ignition_swizch:;_toJOff{l_ositi0n:*;:;-. .. . -. ........•. . ::"_:6....Removestraightpin.

STRAIGHTIGNITI(_N " * "

R_-- !: RES,STORI <_, ooo-ww i [__ _ <<"> W.,T_

' ATT'I )STARTER RELAY ", - GREEIN

__:_ PURPLE NOTE:

WIRE SEQUENCE....... _'_ << [ " HAS'SEEN ARRANGEO

TO SIMPLIFY

O,STR,_UTO.. I> I -I << _LAC_ SC.EMAT,C..... << O..NGE

Page 438: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'.: _'" _:_,";'2_08'"........,,,.... _ ............ ," "-- _."i':, :,,- :;"':'";":.'_"!IGNITION_'SYSTEM:'_"":.:".,;":": ..... " : .... ' ' ' ' " 2-08

.......DIAGNOSISAND,TESTING.(Continued) ;,. ..• ,,.... "•

, TEST STEP• . . ' ....RESULT ,._,: " ACTION TO,TAKE,..' . .....

4 . I_',.BALIZAST:'RESISTOR,' ..... :. :, <' .. , i.... 'i ........ ,,. ..... ' - , ......... " ':.':

';:, ' 1: Separateand inspect'ignition •moduletwowire'" ": _018"t0 1:6 ohms: Problem'is either ' .... '.::, :x,_, :, connectorwith RED and WHITE wires, intermittent or not in "

ignition system."_ 2. Disconnect and inspect ignition coil connector• GO to 5. -

i'--_ 3. Measure ballast resistorbetween BAI-F terminalof _:_:ignition coil conriect0r and' Wiring hi_rness connector Less than 0.8 or greater Replace ballast resistor. , '

_:- mating with RED module wire. than 1.6 ohms_, 4. Heconnect all connectors.

RED

-- I _ 'B_TT'MODULE

@,•" ! NOTE: }

__ 'TAC H' I _ ._. GREEN WIRE SEQUENCE> _" "_ HAS BEEN ARRANGED

' PURPLE

_'> . I I < < BLACK SCHEMATIC•

TO SIMPLIFY

) > [ < < ORANG_< < ,,_,

k jAB379-A

.. . . .

•_:;

_

Page 439: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i _l' '"+°'' ,DIAGNOSISAND TEST.ING:.(Continued) ....

k4z

•...... _"' +-',+l: • ' " " " _90"?peice_"" " 0f'batter_.."" " + ""Test.result:OK.'" '" "r'": I:" " " 1._,:RemoveSPARK'TESTER, reconnect _oil,wire to," ..•' , l ' ..... :,-..distributorcap. • - - _ -. :voltage;;or:greater-: .....; ,+.-GO;to&

_ 7.,....:.,+:.L_:;.,,.._.:,..:_.;:.:2.1:Disconr_ect-cable,from_;starter.relay.tostarter..moto_., : ;'' ' - .........

.. : ':.*",'"V.,,..",_. "._,._,.:.J'.'3_,CarefUllyJnsert,_mall Straight,pins in.:REDand '.t.":."":: ,l"_ss :thah._90{pe_cent:_of::__;.,!Refei;,_to;wirin(_:diagram." ' ' .... i"..' " _., WHITE-module wires. - . . . _ . , .. " ".".,batte_,_o!tage:_.,!.,..!',._'i-.,_i-i!iI !"Idspect;_. ring:harness.

_':._ ":.; I:,._.,-.;:CAUTION:Do'not:allow.straight;pinsto.contact.". . -.....__+..,_-.;.,._,-._/:_.,:_,.:_::_.!i::'::{;and,connector(s)m %' " ' : " : " " -_...electrical.;ground...-. " " . ". " . ":,' : : .._,.:"..:.:._:_;:_I_faulty_;circuit(s). -

_." ::.,.4:,:Measurebatteryvoltage.. : " "'. • ; ".' : -*_:-,., I-_Y,_-,,.I_:0Worn,0r._damaged -• ....... ' "': _:_5.::Following.table'below,:measure .voltagbat_points:" : .....__'_J:.......,,-,-.i,,L_,,/;,._,._,..._,j_ifi;ignitioni:swi{ch_.: " ,.

' .. ..' '-'. ...._ '..:listedwithignition switchJn_.positionshown. - -• ..NOTE

... ;::- :::.:,...,;:,.;%:y_-..:,,,,_!_,:4e_:_Attach_negative;.(::T_),,_VOM;lead,:tO.distributo_,I;:.. :..-..... . -_-:- . . . . • . ..... .base.

• " . .'. "- _'.'J e..Wigglewires:'in'wiring harness when- ' ..":.:measuring.

".',TERMINAL : ". _POSITION -. ,i' "',,.,..,.-:._.._o'." ' ,_-_!_:...---- .:, .-

- . i RED " ": " • " . :.

• ,' WHITE " START ' START"BATT" ...:BALLAST

_!TERMINAL-: " ,":RESISTOR .START .........IGNITIONCOIL " -:BYPASS ' ' - '. - "" .'

" }i ........... ,'_.' ,,. ,;_,6,_".Turn..ignition_switch,4o_.OffpositiOn. . .... ' .... :-: - . ..7. ;:Remove:straight:pins. • .......................... _,.........--_.,..._'._......

............ ,. :..-...',8;_:Reconnectany cables/wires:removed4rom.starte[ ....relay.

.,,,,,,,,,,.,....,_ TO VOM

VOM

q'ACH'_

I - - • IV B,LLAST _1I _-I.,-,_ REOIGNITION [ I !'_ R_ESISTOR II -

SWITCH H I <<10 WHITE+,

STARTER RELAY _ . GREEN

I - --'TACH' << i------

_! _ORPLE NOT_:

W,"E_OO_NCE> << ._s_EE_ARRANG_OTO SIMPLIFY

-I << BLACK SCHEMATIC.

..... I .<< O.ANGE

_ A6360-B

Page 440: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, DIAGNOSIS AND,TESTING,(Continued) .

I m " ' ' '" '''I'_'I ' R _SU[ T:e_ I_ "Irk' I , i .... : ........ . .... ,L_._", ='_'' TESTSTEP j : • ACT,OTOTAKE....I I r

i 6.,:_:,;qGNITIONr:COIL-SUpp.Ey_;YOETAGE,"I';,/-,,,'";';;",.. ............................ ,, .... ,.... . ... :: _....' ..... :1:,"Attachnegative"(=]"lead'of"VOM"t 0 distribL_toi' '_ _ ' 6 'to 8 volts GO to 7.' r ,

"-"_ base.

;:" 2, Tu'r_ ignition switch to Run position. Less than 6 volts or greater GO to 12.3. Measure voltage at BAI-r terminal of ignition coil. •- than 8,volts :.,,

:/,.. ' '4. Turn ignition switch to Off.position:...... .

:L

. :-!i_, q V/

IGNITION . ,@, __SW,TCH_ I . __ _%R,.UTORr ..::. _,'" r. -./ - BALLAST ----I I _......... . . ":RESISTOR:I I" . <.. RED..... o.i.,,

,; [_-7 i " IGN,:r_NT(_' COIL \ '_ / IGNITION

STARTER REEAY _;_--- 'TACH' ;REEN MODULE<< PURPLE

>> << [_

D,'_TR, UTOR _ _ _> "l' BLACK NOTE:>> _ << , W,RESEQUENCEI HAS SEEN ARRANGED

<_{_ OF_NGE TO SIMPLIFYSCHEMATIC.

DISTRIBUTOR STATOR ASSEMBLY AND WIRINGHARNESS

1. Separate ignition module four wire connector. 400 to 1,300 ohms Test result OK.Inspect for dirt, corrosion, and damage. GO to 8.

2. Measure stator assembly and wiring harnessresistance between,wiring harness terminals matingwith ORANGE and PURPLE module wires. Less than 400 or greater GO to 11.

than 1,300 ohms• !

IGNITION i ;_ " '": ........

SWITCH _S= i BALLAST , RED _• | RESISTOR . . ._ _ :';_7..

', _ R= _; J%J_t_/%/_ j _ < < WHITESTARTER ' i',._ : '_ i

, IGN _ _GREEN IGNITIONMoDULE

' _ _ I _11 ,7 BLACK NOTE:

WIRE SEQUENCE

HAS SEEN ARRANGED

_i _ ORANGE TO SIMPLIFYSCHEMATIC. i

NOTE:

, WIGGLE WIRES IN WIRING __ _ _ x-t (p .....

•.;i' "HARNESS WHEN MEASURING

Page 441: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:DIAGNOSISAND TESTING (Continued)

9i) " "....• ' " ...... TEST STEP , : RESULT ACTION TO TAKE .TB o t ,iw .....

...... " ""' ..... "_ ''1_ U OB::S AT R_ASSEMB IRING/,_/.;:"- .. ' "",': _,_;';8_._ DiS RI ....... .... .,.. •.I

4 _

.. :_ . ,,_ .,',_ .. _:- ,.,,." . .... ,

, - _. - ',. :-' ",L.*,;l:,.:Attach0ne..VOM_lead.todistributor:base.... ; ," : ',, Greatel',_thari,'70_000,_ohms_:'..Test_,¢esult'OK.: ,' . •

........ .t,, : _,._.F2:,:_,AlternatelyTneasure-resistance'betweenwiring': ' .... ,"._"' ...... ._.::.__._,......_'."",t_.:' -_,GO!_to"9:,'_ ,..'., "...... -..._._; ..... _ ' ...........".harness_terminals:mating.with;ORANGE.and.,._: , - ' _ , . -. -. , .,,..:..-, -:r .. ,..., .- " "

- " -. ;-, :- .: ,.PURPl_E'module,wires and ground. " i.Eess,(th_n:;:ZO;O_OiOhms-.!,,_!it_dnSPeCt_..wiringharness ...• .- -: :. -... _• ,,_:.:."..*.:3_Reconnect,four.::wtre,;connector.,,.. . - .. .;:- -.._- ' ,',:::.-.';_.between"module'

,. '...... ; ,;)t" :connector/and- : .:.,:.'.:.-.i;_:_distributor,.including

..... . '-';J; (_distributor..grommet•

,¢"ilONI.rlON_ '". _: " - "-.. • . " • It '"-_..... ' . , . :. '. " , " . .; "

• _..-..- . _,_,,s.r,,, I •I.. .,_o[.... •' ' _" , ' ' "RESSTOR ........ _,_q,_ [ "

_'-;' ' "_/:_'R, .... "" _ _"['" << ' " "WHITE I . '

• S_AR_ERRELAY . _ BA_ . " ,:i•;i_,._:/.:iCi.;;,:I,2'_,U,_."i,i..,!_';:. .IGNITION/' /_ _ " " " " ." ' ' " ';::.:.GNTON

' , COL | ._ I . " ...... "" ' _ , .:,_'_MODULE "

• TACH , • •'-:_n_=m

I'_- _ ..f_--'..._-_'_ ...,.r-.----: __*._ '_.1 • " ,:_ PURPLE ' ' '

•. .i.. _........... , ......... _ > • ,,'l-""_--_.,_m,]l_Ei•m:::] J_=:BLACK :', _'_.:'_;WIRESEOUENCE' " ' ' Ii " I ' '. "_,. .. '. / I . '" . ' ' 1_ -_\_U,I_JI_L_II _.= / • -'._.,:'--- :_..;HASBEEN,ARRANGED " " I

• " . ' ....X .... '"/- '-.- ' - ' _", I- "_-_'_k,...'_It_-,=,J.,.OP_NOE , - ",'..'-_LTO.SMpLFY ..... i

_'- DISTRIBUTORBASE

9 i IGNITION COIL SECONDARY RESISTANCE

1.'Disconnect'andinspect ignition_coil:connectorand 7,700 to 10,500 ohms "Test result OK•coilwire...... : ,.

GO to 10.2• Measuresecondary':resistance"from_BAT3.:terminal-

to highvoltageterminal. Less than 7,000 ohmsor Replace ignitioncoil•... 3. Reconnectignitioncoilwire• greaterthan10,500 ohms

!__1II

'BA.rT ; !

IGNITION-'_

Page 442: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

DIAGNOSISAND TESTING (Continued)

r TESTSTEP" I .... 'RESULT " : : •ACTION TO TAKE,.

';IO:.I'.,"MODULE:T.O:'COILWIRE:",:::'.'." .,.- " . I1 ."i i. s'' '' I ..... ":" ' "_'_::_"'_"',_,.- - '

:'_" 1. Separate and inspect ignition module four wire Greater than 100 ohms Replace ignition module.connector and ignition coil connector from coil.

;:, _-

_,_ 2. Connect one lead of VOM to distributor base. 100 ohms or less Inspect wiring harness ., ..,: = between ignition module,; 3. Mea:Sureresistance between TACH'terminal of and coil.._ ignition coil connector and ground. .,-_.

• " 4. Reconnect ignition module and coil connectors.

I .. REDr,,' " " _ _',IGNITION ' ' ' "_" RES., . . ;", ..... '" _ _

m SWITCH . '_ ,R • . . -._ "" " , _ " WHITE• '

2'_ 1': IGNITIO _ _ MODULESTARTER RELAY, COIL I- _ GREEN'TACH' _|

:.;_.. > ) I PURPLE NOTE:WIRE SEQUENCE

> > [ HAS SEEN ARRANGEDTO SIMPLIFY

> > SOHEMA,,CI:" : ORANGE

_ DISTRISUTOR" SASE

A6366-C

11 DISTRIBUTOR STATOR ASSEMBLY : _.... _._,_......

._ 1. Separate distributorconnector from harness. 400 to 1,000 ohms Test res_ilt.OK.Inspect for dirt, corrosion, and damage. Inspect wiring harness

2. Measure sta]torassembly resistance across. .. between distributor and,, ORANGE and PURPLE wires at distributor.. _ • ignition-,module,;:._.,'_, - ",". connector.

,. 3. Reconnect distributor and module connectors. Less than 400 or greater Replace stator,, than 1,000 ohms assembly.

Page 443: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i;i!.i ' 2--13',....::_,2-13._- .," ':-o _ ' . ,,. .. •C_:IGNITION', SYSTEM_:%. ,.- ,. ......

DIAGNOSIS AND TESTING (Continued)

.... ' ;i" _ TEST STEP RESULT ACTIOH TOTAKE

• . '_":_'-_-. ;12".i,1:,GNIT ONoCOL'_PRIMAR.Y:RES STANCE.:" .!., ... :. ' " , . ' '-

., :.'. , , -,.,.., 1:],DisconnecEignition coil connector.. ' :" .,'..;, ,..".,' O.8;to_l.6_:ohms,, :,,_':,,.:_,.__:__Test,result: OK.

" stance' 0 TACR ' ' " ...... ", i _i31. • ., :'_-2.-"Measure'pdmary resi from_BAT-rt ., ' ' ........- ' /.'_,_ GO o

..... " .' " . ,i,.,"it,, ":,.:3:,'_Reconnectignition,coil connector.... " " . _.:,:.....,., .,Less,,.tha,n_O:8_or,,greater_:,%;!_., _Rel_la_ce:_ignitionCOil: _"

' %[

-" . IGNI

• .' .'TACH'

............................ i P,RIMAR¥' ..[i3' ,CIRCUIT.CONTINUITY '

,,'. : ,-.:,,.:b,;.:]_1::Carefully_insert_sma-'straghLp _,in module:iGREEN._ :,Greater,',.than1::54,volts:." ,..: :_GO:t0]14;

;_. wire. , . . . .... .... : ...........) cA ow;,;tra]g ......'......"_";.'_...:":_': uTIoNi_,Do,n0t,_ail ht'-pinto:contact:.',: l.5woltsiorzless',-,_. _!.'_',,_¢_"_:lnspect_vr ng harness., ;. "" : ._ele¢trical ground.. ,. : " .*•_-'_."> :"_ :,and,connectors,between _.

' .2.,,Attach .negative (-_,).VOM lead.to:distributor base.. .. '" .ignitionmodule, and coil.

3. Turn ignition switch to Run position.

4. Measure voltage at GREEN module wire.

5. Turn ignition switch to Off position.

6. Removestraightpin....

" _ BALLAST | I .... R'_r

r

• ,_..,_. ' " ...... i'" RESISTOR'". ' " '1 " L _ . <<• -SWITCH - R _ _ ; _" .-_ I .... ' " . .. . .... ,

.... ...... I << w.,TE,• I'_"-f'_'_r'-_ *BATT ......... :-] " '

. MODULESTARTER RELAY -r-- _-_._ ..

I "_'_ GREEI_

. . , ' ,' _ • • [_ - ,'TACH'

_.___ NOTE:.).> W,RESE_uENCE, _ _ HAS BEEN ARRANGEDTO SIMPLIFY

SC.EMAT,_. "•<< BLAC_

i_ V '

| __-"

A6370-A

Page 444: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, - . , , •

DIAGNOSIS AND TESTING (Continued)

• •.... ....... .i ::iTESTSTEP ' "_:"RESULT . ACTION TO TAKE' : ...:." •i.

,'/14 I ' ICIRCUIT CONTINUITY_.! _ i :. '. - ' L,,':,..GROUND:' :.... _ 'I

I

•'_'_i_ 1. Carefully insert small straight pin in module BLACK •Greaterthan 0.5 volt GO to 15.;_ wire.-;" ...

:.., CAUTION: Do not allow straight pin to contact '_;\' elect_ical ground. 0.5 volt or less Replace ignition module. ";;

•':_.. 2. Attacl_ negative (-) VOM lead to distributor base. ..-.

:,r." 3. Turn_iignitionswitch to Run position. ". ':_. _:

;,_•' 4. Measure voltage at BLACK wire. :.

, 5. Turnii!,._gnit,on switch to Off position• ;L_!,i_:'. ' "

; _",. 6. Remove straight pin. _._ . .... i-:_i_ ...... ,_ . . . .-. ,•,',:_

"_,._"IGNITION .....

" ""' -- -- BALLAST I RED

. 'iR_ '..= _V_-, WHITE

"."

:'__ _ 'BATI"IGNITION _ 't'_

, CO it_.._.._ IGNITIONMODULE

i _ _ GREEN !• #r,: ,_"* 'TACH' r

/"_/ WIRE SEQUENCE

. , :, '_".r' << [ORANGE ToHASs,M_u_BEENARRA.GED'" '.'i" "' .... _ SCHEMATIC. ,_

'?,!

• Y $-) BAsEDISTRIBUTOR

15 I DISTRIBUTOR GROUND CIRCUIT CONTINUITY I :4_'.'

.', 1. Separate distributor connector.from harness. Less than one ohm Test result;_OK.. :

!.,_ Inspect for dirt, corrosion, and damage. ' _',;_."_" "' . ", " •. • Inspect wiring..harn'ess_-.:_... '3' " "' ..: " :_!:,:_"2. Attach one lead of-VOM to distributor base. ' :"_-.;, ' and 'connectors between .... . ,

distributor and ignition:!:_- 3. Measure resistance by attaching other VOM lead to module.:;:, BLACK wire in distributoi"connector.

_": NOTE: Wiggle distributor grommet when Greater than one ohm Inspect ground screw inmeasuring, distributor.

:_: 4. Reconnectdistributorconnector.

F: n

DIST_TOR

Page 445: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'" ...... 15"_''' ' " ' '" ' "'""_I " '' .... . ."::2; "_:':::','""" " " " : GNITION"SYSTEM _!' . . .::.. i._ :...... " " 2:'151......... '/_m ' " ' ......... " " " " '_"" ' ": ' '" " ' ": ...... il .... " i" '" "'". '

REMOVAL: AND,INSTALLATION

_ - -_.'-_(,'.,_'.;DISTRIBUTOR.,, ,:.-.,., . ' 2. Ifengine was not_.rotated_while'distr,ibutor,was._•:' gin..... -,-" : val_.:_,::...... : . al:,di ibutor:,i bein- . . " ....•,"..__.:,-:.:-'.'Remo .... ,', : .rernoved_,and_'.,ori str s: g_,:._,,

.replaced:-...,. : . : -".1':.,.-Remove•distfibutorcap.?pOsition,it'and igni: .... : •., , ........

• " "........ tion"wires to one side. . _ -.- ",. ,a::.;:_P_ositior,idistr.ibutorinengine:withrotor and" ..i._ .:.' :.,.. '_" . ....., : . - ,. :. - - - " - - :::.,":.:-,dstrbutora gningwith.previouslyscribed'. ....., ......,,:_ ,. ......2.._:DIsconnectand:.:plug,,dmp!3rag.rn_asse..by. .::':.':.._::._.'_._imark'...,,Armature"and:statorassemblypoles:

.. . hose(s). , .. •. . .. " ..... : : ".. -.-.:::_L_shbLJii:J!a:lsd:&lign,,:,:if:Clistrib0t0r:iis.fullyseat-; .:,.." ':=. ?: :, ............ ' • , ..... : ,_:.,.ed-.n b ocl_and,, r,oper 4nstalled •Crank::,,....._:3._,:;.Separate:dlstr,.ibuto_:-connectorfrom..wlrlng,. ...... :-: --_--,_: .... . . -,P,,... Y...... .. .

,. " • , ' _.-.. .harness_' ...,, , . .'" . .... . ..... ::!:.,_'.,:"_:.._:::._:!er_gine!if:neceS:sar:y.,_t_._frJIly_;seat_distributor"...... iin:iblock:'' " .... : ....

, "_,. ...." :',.:.,,:_4:.,_;Rotate._engine,.to:,align_stator,.assembly,pole ..... _.......................... , _,..

..... . .... .:and.any_armaturepole. , ,. . .--,,':b_.:_4nsta...... _"dr.strl_b;ut.o.r,_hoddo,w,n_,.bo_. _ t and• • . ' . " ......... :,.::_camp;_do_.:not.:,tghten '_ ,.:::._-,_, .._,:.:.-:.5."_.,.,Scdbe:,a:mark.,on:_distdbutor;body_and_engine:.... " :" • .......... . ." ' ......... '

" " _.',: "_.,,'bl'nck-;to"nclic_te,r_ositi0mof:dstr but_r`_i6`.:.en:_.:.:_._3_`_f`engide_:was:_n_t_r_tatbd_whi_e:;distribut_r.was_' ' ' .:.... ' _';:.......,.., , gine,:_and.positi0n"ofrotor'..,,. ._:_'" - --. : ' ,:" ' "' , ,_,::removedo.and m(_w::d_stributor-:;,s:,,.bein'g.

installed:..... ..... . •_',,6.;:Removedistributorholddown bolt and clamp..

.. a. Position distributor in engine, with,rotor

.. 7;."Removedistributorfromengine. Donot.rotate....... • _:aligned;...wi_th_.prev.iously_,scdbedmark. If..... •.:.,...., .,_:-: :...engine'while:distributo('isrremoved. . ._:,_::;_n_ec.e.s:,31aTy'i!_:Cra,rfk!i:en'-gih.'e_.t6_ifully:seat

:..'.:idst'r'i_utor : .....::" ....... :....... Installation.

• • ...-.-'::1.;:":lf::'engine::was"rotated:.:.whil'e:::distributor"was-- '"-"'-_'b'::::'R°tate'eqgine_until_timing:;marks'for..cor-..... ..removed: ' ,, :._,_:.rect_initial'.timing_align_and;rotor_ispointing

. .... :_ _-::L::_:a:/!Rotate_engine_until.'No::1'piston:isoncorn- ...,...at_No.,&_one_cap,termnal... -, . :.;.pression. stroke. , , •......_:"::?'c?,.::_Rotate_diStfibutor._fin!:block,tot_-alignarma-

• , ,.-_'_4ure:and,stator.:assemblypoles....: ::; :"'..-.:".,_q:i:'b;.:t'Align:.timing,ma_ks;for,co_[eCt_!nitialtiming'._ i:.._,i..:d!,_i_.in:_ia,lli.:d.i.st.r,ibu,to:r_!holddo_/n_bolt and -

.....,. ,, Jc_,Install'distributor-,.with.:r0tor :pointing. at ......,..::::clamp;._do.:not:4ighten:":;',, " _:-.. :' ::.:number:oneterminal:positionJn.cap;:and

armature and stator assembly poles 4. If in steps 1-3 above the,armature and statoraligned. ' assembly poles cannotbe aligned by rotating

distributor in block, pull distributor out of blockd. Make sure oil pump intermediate shaft enough to disengage distributor gear and ro-

properly engages distributor shaft. It may tate distributor shaft to engage a different dis-be necessary to crank engine after distrib- tributor gear tooth and re-install distributor.utor gear is partially engaged in order to Repeat steps 1-3 as necessary.engage oil pump intermediate shaft andfully seat distributor in block. 5. Connect distributor to wiring harness.

.... " ' , 6 Install .e. If it Was:necessa_'toi_crank_:enginei.lagaini:_i,,ii,;.":Checl_ distributor cap. and ignition wires..that igr_iti6nwi_es are.securely con-• '"rotate-engineuntil:,No:':lpiston'is.on"com-, . .

pressionstroke"and_aligntiming marks for nected.todistributor:cap, and spark.plugs.correct initial timing. 7. Set initial timing ,to.specification....

.. .,.. ., ..... _...,.f:..:.Rotate.,distributor,..in_block.,to,,alignarma- 8. Tighten distributor, holddown bolt to.,, ....,ture and.stator assembly poles,and verify, specification.

. . . rotor is pointing at.No...1 cap.terminal.9. Recheckinitial timing. Readjust if necessary.

g. Install distributor holddown bolt and10. Connect diaphragm assembly hose.clamp; do not tighten.

Page 446: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,_,'2-16i_.':'.':_;-..:.". ..... • " ' ,,.... ,. SYSTEM "' _ '; 16 ":_': . ..... ,. ,. : ..... , .... , . • , . • . :_"_- , . .," ,_,._ , .. _ ','

REMOVAL. AND INSTALLATION (Continued)

. .:STATOR_,_IASSEMBLY.._-......,.. ........ " ".",.,.

Remo " • , . Installation:,,s.... •1. Place statorassemblyon lower plate assem- :_'_: 1. Remo_e distributor cap and rotor.

,._.<_ bly and installwave washer (outer edges up),i," 2, Sepai;atedistributor:connector from wiring flat washer and E-clip. .,:;/ :,?_;,.:: harn(_ss._:. 2. Install stator assembly/lowerplate assembly ,.,._; 3• Using_ismallgear polleroor twoscrewdrivers, on distributorbase, being sure to engage.pin '

':_:. remorsearmature from sleeve and plate as- on stator assembly in diaphragm rod. . :',i,..... .. _,._ _:.,_sembly; Use caution to avoid loss of roll pin: 3. Installtwo retaining screwsin proper locations ",.. :_:_.:

4• RemOVetwo screws retaining lower plate as- and tighten to specification. _:

"." semb'!_ and stator assembly to distributor 4, Note there are two locating notches in arma- "base.,_ote there are two different screws..:. , • ture• Installon sleeveand plateassemblywith ':-".

.....:" ,5......Remo_e,lower,plate assembly.and-stator,as,:.,,., .........unused notch:and_new:-ro,_pin.,_!_"_/_,......._.:..... ...

i"_:ii" " "'_semblyfromdstrbutor._.,, • "":.' " ' ' " 5. Connect distributor to wiringharn:ess• "6.., RemoveE-clip,. flat washer and .wave•washer

_._:,._,:,, 6: Replacedistdbutor rotor and cap.Check that: '.._ ' "securing:stat°r'assembly't°'t°wer_plate'as_" ..... ignition wires are securely connected to cap

sembly_and separate stator assembly from and spark plugs....._!_' Iowe_!_i_lateassembly. Note installation of

wave,washer. 7• Check initial timing.

_i DIAPHRAGMASSEMBLY Installation

Removal"_ 1. Adjustnew diaphragmassemblyper instruc- ':,-'

•:_ 1;" Disco,nnect diaphragm,,assembly,,;_acuum tionsincludedin carton."_: hose._' 2•.. Engage diaphragm rod with stator assembly,-r:.

2. Remove diaphragm assembly attaching pin. .!_screws (2) and identification tag. 3. Attach diaphragm assemblyand identification ./'

tag to distributor base with two attaching3. Disengage diaphragm rod from stator assem- screws and tighten to specification.

- - bly pin-and remove diaphragm assembly. -4. Ensure diaphragm rod is properly engaged

with stator assembly pin." ' 5. Connect.vacuum hose...

';,.DISTRIBUTOR CAP, ADAPTER AND Installation_'iROTOR r '_ ..........1::_,._f previousy_removed,post_on.the.dstnbutor..,.__ ;_.': ': _'.,' :_ _!.._

•_'Removal'_' i._'.,rotorwith the 'square and round'Iocator pins.......... matchedtotherotormountingplate.Tighten

i_.1. Remove the secondary wires, screws to specification.

':.."2. Unclip the distributor cap and lift straight off 2. Install adapter in position and tighten attach- '•:'" the distributor• " ..ing screws to specification,,_3. Using a screwdriver, loosen the adapter at- 3; install the cap, noting the square alignment

taching screws and remove the adapter• Iocator, and fasten the clips•

.4. Loosen the screws attaching the rotor to the 4. Install secondary wiies, noting correct ioca-,:. distributor and remove the cap, if necessary, tions on the distributor cap.

Page 447: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

"" , ..-' :..','2.17_'':- .- . " ..... ::IGNITION;SYSTEM';.......'; " : : =, 2,;17_ ' -

REMOVAL AND INSTALLATION (Continued)

":_IGNITION:WIRES. .... SPARK PLUGS', '

..... . ,,._,_,,The,_ig-fiition_/ires_,,iriclude,,th,e._sp&ik;,plug_,wires_._:.,..,i ...... ,.. Removal:::';_.: ...........

" " " '" -..l_;c°nnecting"thedistdbut°rcap"10the.sp ark-plugs-_ ""- " -_.l'i:/_:_Remove_'spark:plug:wireffr°mJspark plug,: " " " " _"1_:._and,the.ignitioncoil_wireconnectingthe distributor. ',. :_.::_!dsing,_051_T7.4_6666:A':or:equivalentwitha. _"-'T/",:.:"::,;:':_]:.:_,:cap!o_the;high,yoltagetei'minal'ofthe_gnition_coil.,,_ • " . _'.,:;;,;,;.:i,,i.,twistihg.'-pullir_g:m'Stio'n:_Do:h0t!pulldirectly on

• , '._._":_:ll."_:.-:These_wires_;are'designed toreduce radiointer-. " :"._"iSl_rk::P'i_gi_vire:"_": - '" ""';: ; ; .. ' , ..'"_ ":"" ":;_:':_:"_1_',,_-,ference!:causeclby.hgh vo tagedischarges _rathe:. ;'°2:i_',_ldspect_'spark":plug_wires:.for_physicatcJamagei: '

' " .,.: _!,.,..',_;:-;.,-_For:'.,testing,,.use;,an'_ohmmeter;and_._checkcre-:., ,..,,-3,-:_.-_iciea_;aiea_ar_un_d_iieaPhispai_ik_iiSlugp'c)rtwith_;" ,:_:"_..i-::;sistance_from;terminal:!in,capto-sparkplug,termi- : ::.,_:,;_:::.:_,dm_esSed_-i_r.:";',_-. ":"! i_i_' :._;..- . ':

;.:.:naDDo:not;,'under,any,circumstances,puncturean .' , ' 4'_-:_-:Bemo_e:_spafk_pu ;,: "; ,__.;_',:"_- .-"".'_'_:; _-_ignition:wre,with::any.,.type-of;;,#robing:.device::;...;.i ............ ....... -, . g.....•.............. . -:• "

•-' .,.".,,;Removal.- " .... - --: " ' " " '_InStallation.:-._ , " _ . '

...... ., ..When..removing-Wires',ifrom_spail<_plugs, use : " 1.,;"Set spark:.pluggapto'specification."-,.,.i;: Tooh]74P._6666-Aor equivalent; Grasp and,twist ' 2.....Install spark plug and tighten to specification...

:...,the.spark plug wireboot back.and forth,.,thenpull,. ...:3.,,_Goattbeinside;of;the,sParkplug_wirebootwith.-.,,,,.,,,. :.:.,,.,the,,w_re_',off;the:_plug.:,Domot;;pulldtrectly.on_.the ' :;"" - ,.:::.:'.-_:,_=l.ic0ne_compound_and_nstall;_on':sparkplug.

: ...... ,: ;-,'_spark.-plug.'wire,or..it.may-_separate:from'itstermi- _ ....- . ._. '._ -.. .- .,- ,:;_,:-.._ ".......'_ .__-;.-;.._:.,:,_nalinside.the,spark_plug.wire..boot...',...........................'; ......

' ._;i;CEEAN ING_AND i;I;NSP_EG_ION.; SPARK PLUG WIRE ....." " . REMOVAL TOOL .... _ ; -" _""" ' .... '" "! "': ....... " ' ' _'"-_

....... %::T,74P_6666_A ..........

_.::\,.l:.._,,_,Clean._diSt_ib_Jtor_.iJsing_dornpressed:;ail)!_Mgk_:...:s r,-" - sureno metal:chipsadhere.to stat0r .assembly.Inspect distributor to be certain all componentsare securely attached andstator assemblymovesfreely. Check that sleeve and plate assembly ro-tates freely on distributor shaft.

TWIST & PULL

' B3496-1C

............................................... DISTRIBUTOR CAP' AND ROTORInstallation

. Wheneveramignition_wire'isremoved'from'a" Wipe the distributorcap and rotorwitha clean• sparkplug or ignitioncoilor distributorcap termi- cloth dampenedwith soap and water. Remove

...... :,nal,. silicone,compound,must.be. applied to the any soap film and dry withcompressedair.

_., ,,-',spark-plugwife:i_ootbefore itis reconnected. Examine for cracks, carbon tracking,dirt.or, Usinga small clean tool, lightlycoat,the'entire missingcarbonbuttonin cap,.Replace as neces-inner surface of. the boot with Ford.Silicone,Di-

sary. Review DistributorCap and Rotor Installa-electricCompou'nd (D7AZ-19A331-A or tionand Removal.equivalent).-

1. Attacheachwire to proper terminal of distribu- itor cap. Be certain wires are fully seated onterminals.

2. Remove wire separators from old wire set andinstall them onnew set in approximately sameposition.

3. ' Connect wires to proper spark plugs.lnstallignition coil wire. Be certain all wires are fullyseated on terminals.

Page 448: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.CLEANINGAND.INSPECTION (Continued) "! _,.,

?I.... 1...........•":SPARKPILUGS --"'..... , CYLINDER:NUMBERING _':AND_I=_':..i_'_• ' - " • . ...... , ' DISTRIBUTOR, LOCATION:'J.". '"

:!_" I '_,Examine t_e spark plug for cracked ceramic

" ,I :insulat°randiconditionof firingend.Referto page ___

,,_., I" ';O2-19,,._for vari0us,!:.._,,,conditionsand actions. FRONT _ DISTRIBUTOR ..i_;'j . _,:!!

! JGNITION _IRES ",r :;' .i'_i_! '.__. Without r_moving wires, inspect for visible FIRINGORDERANDROTAT .ON ,-.._!damagesuchas cuts, pinches,crackedor torn.._boots:_,,,Replaceas:necessary.-,'_:...: ,._, " , CLOCKWISE.'_"_I;'_

'_ '"_ FRONT!

:IGNITION ,COIL CAPCLIP CAPCLIP. : . POSITION POSITION

.oWipe coil_!towerwith a clean cloth dampened FIRINGORDER-- 1-5-3-6-2-4•,i,withsoapanldwater.Remove any soap film and_i_dry withcompressedair. Inspectfor cracks, car- BTDC ATDC""bon tracking!_/anddirt. I TDC I

,;,._,_:,:..' ,"_._,,;'" ...! . "..:',", _.' "-j-'. ......... FRONT_

.-... TIMINGROTATION la_ MARK

.... CRANKSHAFT TIMING MARKS

4.9L

., _ :.

'.i

' "i?

Page 449: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• ------ ------ -_- , ; 2'19!•• • ........ ,:: ,.. jGNmON,_SYSTEM!_,:_::::. ....... _

CLEANING AND.INSPECTION (Continued)

GAP BRIDGED oIL FOULED

I_,

• :" " : _ '; ,_. : .,'. _._ IDENTIFIED 8Y..DEPDSlTr,; .'_ _ :":" ._ _ ' " ! : "_ ' " "_" ' "J%_" "" " " " " R" :' '" _ t _: "'; ;_'_" - ..... "" _:; ..... S "_ _ll ',-SHELLL-BOREE_LECT ODES..,, I

.... •G". _.• :_r BU LDUP'CtLOS NG GAP . .._..".... , -- .. " '1".. _"_: .''l "-t_ I1_'_,_"--_ _'"" '_'" ' ' " "'_! ' I• • • .... :, "'...:- L-_"BETWEEN EEECTROOES."" :f"-';':," "_":" "" ..... ' .-|:':':_:.,_:_:.":_, _'. ,':'C_USED'_B:'(_E'kCESSIVEOtL "I

• . ' '" ' : :" - ""':".'2-.'_ .................... L' . ._1 i' -L',,-':" i _' _:_,"EN_TER NG COMBUST ON 'I"_ "''' " ._. : _.'CAUSEDBYO EORCARBON' "','_" _.. ....... "" " I ".=' ,.'.-" _ :__illl_r..ll _ '" H' " R_'" " '

.... _':'_:,::':'_, '.""_OUL,NG•'.REPL'ACE'"_UO::_:::",':'._:.:_?'_ "_":'::'::'!:I;:_:';':'_:_":_ l:':'!_"_i'C,'N_'_"_,_Og_2w°"" "'_"I "_'I

......... ' . ,,-- -,,.'...'. _1 _ < '', " " '_,cl'",'. _,'_ k_" ;'_'_:_BEIWEEN,VAEVEGU DESAND I.... ; ........ EXCESS VE THE PLUG CAN "_ ....... " '_ .. ................. _ ' " _"

Il t

a

• " : " ,CARBON FOULED NORMAL - PRE-IGNITION '

, , _ "!11 '_ _ _ .. ,..,/I ............ .,_.,_,:,,__.;..,,..__ . I

,..'"_"_'i ............ ' " ,1": .' .... :_ ,. ' " '. "_ .t:':'."-_l ': ...... .

_'_:_"_" ' • ., _," -,_i" ,2""B . _. . • ,; ,;_?-_:...'._ :._ "_:" _ i

IDENTIFIED BY BLACK. DRY FLUFFY IDENTIFIED BY LIGHT TAN OR GRAY IDENTIFIED BY MELTED ELECTRODESCARBON DEPOSITS ON INSULATOR DEPOSITS ON THE FIRING TiP. AND POSSIBLY BLISTERED INSULATOR.TIPS, EXPOSED SHELL SURFACES AND METALIC DEPOSITS ON INSULATORELECTRODES• INDICATE ENGINE DAMAGE.

CAUSED BY TOO COLD A PLUG, WEAK CAUSED BY WRONG TYPE OF FUE L.IGNITION, DIRTY AiR CLEANER, INCORRECT IGNITION TIMING ORDEFECTIVE FUEL PUMP. TOO RICH A ADVANCE TOO HOT A PLUG I_URNTFUEL MIXTURE. IMPROPERLY OPERAT- VALVES OR ENGINE OVERHI_ATING.ING HEAT RISER OR EXCESSIVE REPLACE THE PLUG.IDLING. CAN BE CLEANED.

OVERHEATING'. '.' , FUSED SoOT DEPOSIT

IDENTIFIED BY A WHiTE,OR LIGHT

GRAY INSULATOR WITH SMALL _:_i!i::__::i:i!!i_t_::_ _::ii_i.BLACK OR GRAY BROWN SPOTSAND WITH BLUiSH-BURNT " I i IDENTIFIED BY MELTED ORAPPEARANCE OF,ELECTRODES•" I 'SPOTTY DEPOSITS RESEMBLING " -

BUBBLES OR BLISTERS,..CAUSED BY ENGINE OVER-HEATING,WRONG TYPE OF . CAUSED BY SUDDENFUEL, LOOSE SPARK PLUGS.TOO ACCELERATION• CAN BEHOT A PLUG, LOW FUEL PUMP CLEANED IF NOT EXCESSIVE.PRESSURE OR INCORRECT OTHERWISE REPLACE PLUG•IGNITION TIMING. REPLACE ITHEPLUG.

B4230-2A

Page 450: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3.01 ' FUELSYSTEM '" 3-01

_ Part 3..... Fuel System

SUBJECT PAGE SUBJECT PAGE

. .IDENTIFICATION' : ._3-01 HOLLY1940ONE,BARREL;CARBURETOR

DESCRIPTION................................. 3-03 DescriptionandOperation.................... 3-05DIAGNOSISANDTESTING . Adjustments:. ' 3-08

General Information 3-02 Disassembly 3-08Charts...................................... 3-02 Cleaning..................................... 3-12PressureandCapacity(Volume)Testing....... 3-04 Assembly................... .................. 3-12

•REMOVAL,ANDINSTALLATION.,

-. FuelPumpAssembly_....................... _.... 3-05

IDENTIFICATION .DESCRIPTION

_ .... The carburetoridentification,tag is attachedto ,.. The ;fuel•.syStemincludes,a. mechanical fuel: theupperbodyof the carburetor.The basic part . pump:it ismountedonthe:lower,left-centerof the,,numberfor:all carburetors is 9510. To procure _engine:cylinderblock.-Thedisposablefilter is Io-.replacementparts, it isnecessaryto knowthepart caredon_thefuel pump body.

•numberprefix.andsuffix. .The,fuel pumps,are mechanically'actuated by• means.ofthe fuel pumprockerarm andan eccen-•tricon_thecamshaft.

• The Holley_1940carburetor iscovered in detailPA.TNO_EF,X f _ PA.TNOSUFF,X later in this section.,,.o,cAr.N_. / .-_ \ \

,,_ 9350

DESIGN CHANGE YEAR MONTH DAY

ASSEMBLY vIZgO-tP i :i_i_)

CODE _ :.

EXAMPLE: JULY (G) 21, 1986 , i _

• F, LTE R HOUSING-9355 _:i_':i_

BZ322.tD

Page 451: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3-02 "FUEL_SYSTEM _ 3-02

.DIAGNOSISANDTESTING. '

..GENERAL .INFORMATION " Air leakage in the fuel inlet.line can cause Iow._'fuelpump pressureandvolume.

Water and dirt that accumulate in the fuel tank A restricted fuel tank vent can cause low fuelcan cause a restricted fuel line or filter and mal-function Qf the fuel pump or carburetor. Conden- pump pressure and volume and can result in col-sation, which is the greatest source of water lapsed inlet hoses or a collapsed fuel tank. ; J

• ,entering the fuePtank,'isformedby moisture in the Low pressure is the most likely fuel pump trou- ,,air when it strikes the cold interior walls of the fuel ble that will affect engine performance. Low pres-tank. sure will cause a lean mixture and fuel starvation . -_

If the a'_cumulation of dirt and water in the filter at high speeds.is excessive the fuel tank should be removed and Dirt accumulation in the fuel and air passages,flushed, ahd the line from the fuel pump to the tank improper idle adjustments, and improper fuel levelshould b_!'blown out. are the major sources of carburetor_,t_oubles.

CONDITION PROBABLE CAUSE ""

Low Fuel Pump Pressure • Diaphragm stretchedor leaking. • Fuel line crackedor broken.

• Fuel pump diaphragm spring is • Fuel pump valvesseatingweak. improperly.

• Cam eccentricworn or undersize. • Dirt in fuel tank and/or lines.

•, • Fittings loose or cracked. • Fuel tank vent restricted.

• Fuel pumpscreen clogged. • Diaphragmruptured.

Low Fuel Pump Volumewith • Fuel filter clogged. • Restrictionin fuel supplyline toNormal PressUi'e fuel pump.

• Fuel pumpto carburetorinlet line' '_'_.-obstructed, crimped or leaks.

Fuel Pump Leaks • Diaphragm defective. Fittings loose. ._:Fuel Pump Leaks Oil • Fuel pump retaining bolts loose. • Mounting gasket defective.

Fuel Tank and/or Inlet Line • Fuel tank vent restricted.Hoses Collapsed

Flooding or Leaking Carburetor • Cracked carburetor body. • Excessive fuel pump pressure.

• High fuel level or float setting.

• Fuel inlet needle not seating _:-properly or worn needle and/or :seat.

Hard Starting • Improper starting procedure causing • Incorrect fuel pump pressure.a flooded engine.

• Dirty air cleaner element.• Improper carburetor fuel level.

• Improper idle adjustments.

• Sticking or incorrectly seating fuelinlet needle.

Stalling • Incorrect idle fuel mixture. • Carburetor icing (cold, wet orhumid weather).

• Engine idle speed too slow.• Incorrectthrottle linkage •;_

e Dirt, water or ice in fuel filter, adjustmentto carburetor.

• Fuel linesrestrictedor leakingair. • Cloggedair bleedsor idle

• Fuel tank vent restricted, passages. _

• Defectivefuel pump.• Leakingintake manifoldor

carburetorgaskets. • Excessiveloosenessof throttleshaft in bore(s)of throttlebody.

Page 452: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,, ';3-03 -FUEL SYSTEM " 3-03

/DIAGNOSIS AND ,TESTING (Continued)

"' .CONDITION PROBABLE CAUSE

'_RoughIdle • Incorrect idlemixtureadjustment: • Idle air or fuel passagesrestricted._

• Idle adjustingneedle(s)grooved', e Idle dischargeholes restricted.worn, or otherwisedamaged.

, .e Excessive dirt in air cleaner..'• Idle air bleedsrestricted.

. .' •.High or Iow::fl0atsettihg/_ .':' . '_-e'Accelerating pump discharge'check

valve not seating properly.

,Poor Acceleration _. • Poor acceleration complaints,fall ....... • lncorrectaccelerating pump strokeunder one of three headings:tthe ......._.':.adjustment. -.

, engine is,sluggish on acceleration,.... . .... , •the engine stalls when.accelerated ._ :• Acceleratingpump:fuel inlet or

' or the en_]inehesitates,or.develops " "-outlet valvenot seating.- ...... , ' a flat spot when acce!erated. Poor ....

• acceleration is caused by either an. • Restriction in the acceleratingexcessively lean or rich mixture on pump discharge passage.acceleration and/or defects of ....' ,improper adjustments in the ignitionsystem.

.,' . A LEAN MIXTURE CAN BE CAUSED_ .."ARICH MIXTURE CAN BE CAUSEDBY: "'BY:

• • Low fuel pump pressure, . ' • High fuel level or float setting.

• .,Stickingfuel inlet needle. • Fuel inlet needle not seating

• Low .fuel.level or float settingi." ' ,properly or worn needle rand/or' seat.

• ,Restriction in'main:fuel passage. ,_e,iExcessivelydirtyair :cleaner;,_,._';

,e Air leak.between the carburetor and • Incorrect accelerating pump strokethe manifold caused by loose adjustment..mounting bolts or defective gasket.

• Restricted air bleeds. '• Air leak at the throttle shaft caused

by a worn thrqttle shaft. • Worn or damaged main meteringjet.

• Accelerating pump outlet valve notseating properly.

Inconsistent Engine Idle Speed , • Incorrect'throttle linkage adjustment • Excessive,looseness of throttle 'to carburetor, shaft in,bof'es of throttle body.

•• Governor not.adjusted properly or ,• Incorrectly-installed throttle plates..faulty.

• Sticking fuel inlet needle.• Binding or sticking throttle linkage.

• Sticking carburetor throttle shaft.

Surging Above Idle Speed • Clogged main jets. • Clogged fuel filter or fuel pumpfilter screen.

, • Improper size main jets.• Distributor vacuum passage"

• Low fuel level or float setting, clogged.

, • Low fuel pump pressure or volume, , ,

Reduced Power,Output. • Float setting too high or too low, • Restriction in main fuel passages.

• Fuel pump pressure too low. • Excessive dirt in air cleaner.

• Improper size or obstructed main • Throttle plate not fully open..jets.

• Faulty choke operation.• Restricted air bleeds.

• Improper throttle iinkage orgovernor adjustment.

Page 453: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,3-04 " FUEL!.:SYSTEM. " 3-04II I I II ',-

DIAGNOSIS AND TESTING. (Continued) .... ,

: PRESSURE AND "CAPACITY: (VOLUME) .•TESTING

To determine that the fuel pump is in satisfacto-ry operating condition, tests for both fuel pump FUELOUTLETHOSE ';.pressure• and fuel pump capacity (volume) should ,OSER_STR,CTOR :. ,,_

• _ _/PRESSURE GAUGE .

be performed.,_ ;._ _ ._ _.,__=-_ _ .'o

' The tests are performed with the fuel pump

,. installedon._ the engine and the engine at normal '. 'i:.J, CARbuRETOR FUEL tNLET PORT

operatmg;!!temperature at idle speed. . p

fuel filteri,has been changed within the re'corn- i_

" mended:maintenance interval. When in doubt, I ,,

install a new filter. '_"Pressure Tests

Refer to the fuel pump specification and note . r FUEthe fuel pump pressure and capacity (volume) / TOCA.8u"E'O"_ %.._'L___\ I

design t0,erances. FUELCO_,TA,NE" _EN FFA_IIp::__

1. RemOve the air cleaner assembly. Disconnectthe fuel inlet line or the fuel filter at the car- Eburetor. Use care to prevent combustion _ 826_o18

, due to fuel spillage.

2. Connect a pressure gauge, a restrictor and aflexibie hose between the fuel filter and the

carbui'etor. NOTE: Inside diameter of.small- _iiest passage In test flo,w,circultmust not besmaller than .220. ' ' :..... _..... _...........

3. Position the flexible fuel outlet hose and the Capacity (Volume) Test -.,_..

restrictor so the fuel can be discharged into a With the fuel pump pressure within specifica-suitable graduated container, tions, test the capacity (volume) as follows:

4. Before taking a pressure reading, operatetheengine at the specified idle RPM and vent the 1. Operate the engine at the specified idle RPM.system into the container by opening the hose 2. Open the hose restrictor and expel the fuelrestrictor momentarily, into the container, while observing the time

required to expel one pint. Close the restrictor.5. Close the hose restrictor, allow the pressure One pint or more of fuel shoul'd_be expelledto stabilize, and note the reading. (Refer to the

Specifications in Part 8). within the specified time limit..,:_;_,,If the pump Volume is below spe'_ifications, re-

If the pump pressure is not within specifications, peat the test using an auxiliary fuel supply and aand the fuel lines and filter are in satisfactory new fuel filter, lf the pump volume meets specifica-

_condition, the pump should be replaced. _",i_0nswhile using the auxiliary.fuel supply, check ....If the pump pressure is within specifications :'_fora restrictionin the fuel supply from the tank and

.._perform the tests for fuel capacity (volume). for the tank not venting properly.

.... ';'_:_

Page 454: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

", .3-05 FUEL"SYSTEM 3-05

REMOVAL AND INSTALLATION

-_ FUEL:RemovaIPUMPASSEMBLY, ._

1. Disconnectthe.inletand outletlinesatthe fuel 2. Positionthe new gasketon,the:pumpinposi-pump. tionagainstthemountingpad..Makesurethe

....2: Remove the pumpattachingscrews,thenre- . rockerarmisridingonthecamshafteccentric.,....... move the pumpand the gasket. Discard the :(Turn.theengineover until:thefuelpump ec-

gasket. , centdcJs on the:lowsideof the.stroke.)

Installation - 3. Press the pumptight againstthe pad,.installthe'_attachingscrewsand alternatelytighten

1. Remove all the,gasket material from the them=to,specifications. "mounting•pad and pump. flange. Apply oil-

. : resistantsealer to,bothsides of a newgasket • • 4. Connect;the fuel_:inlet,and :outletilines.• " .,• and to the threads on the.attaching bolts..... '.,5. Operatethe engine and check for leaks:

HOLLEY 1940 ONE-BARREL CARBURETOR

'. IDESCRIPTION ANDOPERATION

" The Holley 1940one-barrel carburetor used on "• - ANG " . ._ this engine includes four'basic_fuelmetering sys- FLOAT'T iii "_ J

,._,-tems.The idle system provides areasonable rich I _ F _:,mixturefor,smoothidle,and a.transfer system that /:, operates during':lowspeeds. :The main metering.. • sYstem provides the most economical mixture for .... 2

normal cruising conditions. The accelerator pump " "system mechanically provides additional fuel dur- -ing acceleration. The power enrichment systemprovides a richer mixture when high power outputis desired. In addition to these four basic systems,there is a fuel inlet system that constantly suppliesthefuelto themeteringsystems•

The choke system supplies a rich mixture tostart the engine when cold and a slightly richer FUEI.ANDINLETvALvEFITTINGthan normal mixture ,for,,cold engine operation..... FtOATThe 1940 carburetor is-equipped with_ a handchoke located,on the dash.. ,

FUEL INLET SYSTEM

All fuel enters the fuel bowl through the fuel inletfitting in the carburetor body. The "viton" tipped The fuel inlet system must constantly maintainfuel inlet needle seats directly in the fuel inlet the specified level of fuel as the basic fuel meter-fitting. The needle is retained by a cap that permits ing systems are calibrated to deliver the proper

' mixture only when the fuel is at this level. Whenthe fuel to flow out of holes in the side of the cap.The designof the fuel bowl.eliminatesthe need for . the fueHevel in the bowl drops, the floatalso drops

permitting additional.fuel to flow past the fuel inleta fuel baffle.The fuel inlet needle is controlled by adual lung nitrophyl (a closed cellular buoyant ma- needle into the bowl.terial which cannot collapse or leak) float and a The float chamber is vented internally into thestainless steel float lever which is hinged by a air horn. At idle speed the float may be ventedstainless steel float shaft, externally to the fuel canister.

Page 455: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3-06 " :FUEIZSYSTEM 3-06' II I I II [; _" ' ." ' "

HOLLEY 1940:ONE-BARREL CARBURETOR,(Continued)

IDLE;SYSTEM MAIN METERING.SYSTEM, ' ,

•Fuel.used during curband lowspeed operation ,: As the engine approaches cruising speed, theflows through.:_othe main jet into the main well. increased air flow through the venturi creates a

An angulai" connecting idle well intersects the greater vacuum (low pressure area) in the venturi ,_main well. An idle tube is installed in the idle well. of the carburetor. Near atmospheric pressure pre- . _...... .,_,_

• Fuel travels into the idle. well and through the , sent in the b4)wl above the fuel causes the fue_ to - :-.restriction into the idle tube. This metered fuel flow to the lower pressure area created by the

•mixes with.'a'ir which enters through the idle air venturi and is magnified by the dual booster .

bleed Iocate'_ in the fuel bowl cover, venturi. :_!i-4'At curb idle the air and fuel mixture flows down Fuel flows through the main jet into the main

the idle channel and is further mixed or broken up well; air enters through the main we_l air bleed and' by air enter i_'g the idle channel through the trans- into the main well through holes..in4he main well ".....

.. "fer slot which is above the throttle valve at curb tube. The mixture of air and fuel I_ihg'lighter than::"idle. raw fuel responds faster to cha_gesin venturi

vacuum and is also more readily ;Japorized whenDuring low speed operation the throttle valve discharged into the venturi.

•moves, exposing the transfer slot to manifold vac-uum and fuel begins to flow through the transfer The main discharge nozzle passage is a part ofslot as weli_.'s the idle port. As the throttle valve is the dual booster venturi, which is an integral partopened fu_er and engine speed increases, the of the main body casting. Distribution tabs in the.air flow th_ugh the carburetor also increases, main venturi provide the proper distribution of the'This increas_e air flow creates a vacuum or depres- air-fuel mixture between cylinders for specific en-sion in "the:_:venturi and booster nozzle and the gine applications.

main meterilng system begins to discharge air and The main metering system is calibrated to deliv-fuel. .,_. era lean mixture for best overall economy. When

,:. additional power is required, a vacuum-operatedpower system enriches the air-fuel mixture.

MET ,])k__ _ I N-_,_ _

IDLE MIXTURE SCREW

METERING JET MAIN WELL

Page 456: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i

• "3-07 ' FUEL SYSTEM 3-07"'"! I I I "'.

HOLLEY 1940 ONE-BARREL CARBURETOR (Continued) _ r ] _

'..POWER.ENRICHMENT SYSTEM .... • ACCELERATOR PUMP SYSTEM "_:', ." MODEE_1940 "

' " " " When the throttle plates are opened suddenly,_The power enrichment, system consists of a ,the air.flow through the carburetor increases al-

.. _:power valve installed near.the center of the car- .. . most.immediately; however;,there is a brief time....... .buretor body and.avacuum piston installed, in the ..:_ 'interval:or lag before the fuel can overcome its:, ' . ' bowlcover:;Avacuum passage leads from the top .'inertia,and .attain/required. fl0w tb'. maintain the ,_

. , of:the piston down to the manifold.flange, desired .air-fueliratio,

: . '- : ',When themanifold vacuum is high; the vacuum-, .;,The:piston:type accelerating PUmPsystem me-., :piston is:raised:to.the.top.of, its cylinder and the. _chanically:supplies_the_:fuel necessary to over-

, spring onthe piston is compressed .... .:. '_'comethis deficiencyfor,:ashort,period of time.'

When themanifold vacuum drops toapredeter- - , " Fuel enters thepump cylinder=fron_ the fuel bowl, mined level, the spring overcomesthe vacuum, ' :through :the.pump.cup stem .clearance hole when

• and:-pushes thepiston"stem, down-..'-.The piston, the pump is lifted to arefillposition. The fuetlevel" " : stem in turn pushesthepower valve down, open .... is above the normal position of the pump piston.

ing the power valve and permitting fuel to flow This is known as a wet pump system.• through the power valve, through the power valve

channel restriction and into the main well located As the throttle lever is moved, the pump link._ near:the power valve. . . , operatingthrough a_systemofJeversand a drive

spring;pushes.the pump piston down, seating the• . , Thepower valve, originally,used in the model pump cup:against:the,face,of_,the, stem, Fuel is

.1940 isa three-piece valve sold as an assembly, forced-through.a passage.around.the pump dis-,,•..Eater.model ,•1940 carburetors useda one-piece, 'charge:jet,,,which ,is drilled in the main b-ody.two-stage power valve.

_ .When:the.,pump, is-not in:operation, vapors or':bubbles forming, in :the.pump cylinder can escape.through the•stem clearance hole of the floating

' pistoncupand past the pump stem.FLOAT VACUUM PISTON " " • 1 ' : ' " ' :_ _ ': _"

, _ ' PUMP PUMP DRIVEOPERATING SPRINGROD

PRING PUNLINK

PUMPMAIN WELL MAIN JET CHECI( BALL PISTON AND

WEIGHT STEM ASSEMBLY

Page 457: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3-08 FUEIzSYSTEM 3-08 _:.....

HOLLEY 1940.ONE-BARRELCARBURETOR (Continued) : ;,

ADJUSTMENTS DISASSEMBLY ""

REPLACINGIDLEMIXTURE SCREW "' The model 1940 carburetor is assembled ofthree major sub-assemblies. These assemblies

Reinstall the:idle mixture screw and turn screw are the air horn or bowl cover, carburetor body : ._ilightly against its seat with the fingers. Back off the assembly and throttle body assembly. Servicing of , _exact numbe(0'f turns recorded during disassem- the carburetor can be simplified if these sub-

-'bly. With the id!e,speed screw backed 'bff and the' assemblies are disassembled and kept together in :.,throttle plate c(_mpletely closed, check the PUMP their respective groups. ,_:_PISTON STROKE ADJUSTMENT (distance fromthe vacuum p_sage casting to the center of the THE FOLLOWING PROCEDURES APPLY TO

:.hole in pump!_perating rod). THE MODEL 1940

SPEED_i_-DJUSTMENT_-_:3 1. Remove nut and Iockwashe(i_etaining the_IDLE

:A stop screw,controls.the, engine idle .speed, pump rocker arm and pump linki.-"Run the engine until normal operating tern- 2. Remove the bowl cover scre,hE:

: perature has been reached. Turn the idle stop Note the position of the link In the rocker armscrew "in" to increase the enginespeed and "out" slots and the position of the throttle returnto decrease th'e engine speed, spring or the positive throttle return spring on,_,_,

CARBURETOR IDLE MIXTURE some model applications for proper;:ADJUSTMENT.,(ON ENGINE) reassembly.

CAUTION; Idle speed and fuel mixture adjust-ments must be made with the ENGINE ATNORMAL OPERATING TEMPERATURE and _;

engine air cleaner in place. /

1., Connect t_thometer to engine. Tachometer.must be 1%-2% accurate andhave expanded _,,:,,,_scale of 1-1000 or 400-800 RPM. _' ,_

2. Be sure engine is thoroughly warmed up. Ad- ;;just "idle speed" screw to specified RPM peridle speed adjustment.

Turn the mixture adjusting needle in until the UNKengine begins to run rough from the lean mixture.Slowly turn the needle out until the engine beginsto "roll" from the rich mixture. Then slowly turn theneedle in until the engine runs smoothly. Always "_"_

favor a slightly rich mixture rather than a lean _::_,setting :_

It may be necessary to reset the idle speed stop ._,screw after the correct idle mixture is obtained.

Page 458: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

',3-09- FUELSYSTEM i 309'".2 • .' ii, ii :_ ;

i, HOLLEY 1940 ONE-BARREL CARBURETOR •(Continued)_

3. Separate the bowl.cover from the ,carburetorbody.Do notpry,,,Tap gently from,side toside.

..... :,.- " with a.plastichammer or screwdriver handle.-. ,i._0_:: ....";?i_iiii_

4. Remove the accelerating pump operating rod _.ii ;;:y .retainer screw and retainer. ' ,.

:. 5. Rotate the pump. operating rod:and discon- '' . nect the pump drive spring and accelerating :_ i'.

.... pump assembly: Set ,the pump assembly.a-. _. "i. _i)}_, .. , side. Do not immerse incleaner. Anew pump .... :cup is in the kit. , . ... _,.:i,/'_" _i

.ACCEtERATOR i' " :" ' "'_ '

Pu_P _.4

• 8... With asuitable pulleror'longnosed pliers andsuppor.t, .remove.'the. vacuum piston

ACCELERATINGPUMP assembly.PUMP ROD I_ETAINER OPERATING ROD , '.,. .... ':' . '

• , ....,,#po,_....MAIN WELL TUBE

• ' °_.4D'. " '" . PH173 ./ .... - ....... :;2.1",PLIERS ; , . _P,.___'Z

O ota,e,,e moooera,n ,roOanOrerr,ovethe rod and grommet from the bowl cover. _//_.. f__.-,_ _.| _Ni _, _)

_L _:-'_'_'_l_.,_h( _ VACUUM PiSton

_!" " HAMMER mr.lsJss

9.' Remove bowl vent valve from rod if soequipped. The rod cannot be removed.

10. Remove hot idle compensator valve cover,MT.,S3_ valve and gasket from cover, if so equipped.

This normally completes disassembly of thebowl cover. If the carburetor is equipped with amechanical power valve modulator rod it cannotbe removed.

7. With a bearing scraper or a scraper ground CAUTION: Unless the choke valve is bent orfrom an old triangle file remove all the staking damaged DO NOT REMOVE the choke valvefrom the vacuum piston retainer, screws, valve or shaft for normal service,

Page 459: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:3.10. • ":FUEIZ;SYSTEM :_ 3-10 _.

HOLLEY 194OON E-BARREL; CARBURETOR (Continued),, ...... ,.., "..

, .. . .. •

CARBURETOR BODY DISASSEMBLY . 3. Remove'the main jetwith a jet wrench.A 3/8" • _,:wide square point screwdriver maybeused. ' _-

1. ,,Turn the carburetorbody •upsidedown:'and :,,,. ...... :. ..remove;the pump discharge ball and weight. _.Save the old ball in case the seat needs /t. . ................

staking_i'.` ,:j,,_,_,_:- ' _m,_._..... _,__;;"_,_...,; _j'

/MAIN B 0 D_"

""::"-"4 ;::_ -.._..z.'; I :-'.,;'

II

MAIN JET_.

_" JET WRENCH

PUMP DISCHARGECHECK BALL

_V EIG HI" _ ,'.IU' Mr.I S.1_1• . Mr.,,_ _;!

" 4. Removethe power valve assemblywith a: : ' ' " ' _' _'";:_ " ' proper socket or a 3/8" wide screwdriver blade

2. Remove the fuel inlet valve and fitting assem-. • with a 1/16" x 3/8" deep slot sawed in thebly; remove gasket. Remove spring floatshaft center of the blade. The slot will clear the "ii:iretainer, float shaft and float. power valve stem and prevent damage.

n _

i. FLOAT " _.x . " .... "

F,LOAT RETAINER / SOCKET WRENCH

SHAFT __,/ " ....

_t; MT,|336!

•_ MT.IJ364

Page 460: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

..'3-11 FUEL" SYSTEM 3-11II I .II • II I I

HOLLEY 1940 ONE-BARREL CARBURETOR:(Continued) -.

This_completesthe,,disassembly of thecar- • THROTTLE BODY DISASSEMBLY _buretorbody.,Removethe,threecarburetorbody-:.

•' ;i_ .to-.throttle:bodyscrews.Tapgently_andseparate., 1. Gently turnthe idle mixture screwclockwise: thethrottle body from the main body. until it,seats. Record the startingpositionof

,,,.they slot and,the exact number of turns re-quired :to,seat,the ,screw. This procedureisnecessary_to,reinstallit,,in,the,samepositionafter cleaning.

2. Remove the,curb.idlescrew and spring,low:,. .. -:idle_screw_andspring-andfast idle screw and

.',i' ' . ,ilspring:.:Certain,.;applicatiohs:maynot have all__- _.._, • of-ihesescrews:_.. . , . . '.-: ,.'"

GASKET "FAST IDLE STOP .

'SCREW ' " LOW'IDLE SPEED\ / scREw

" SPRING-_ ,'_ //., SPRING

THROTTLE BODY CURB IDLE tll_ t /_-, "_1_ _' .SPEED , _ - ._ ,_._,.., " _'O

[ SCREw ! ] i

.' SPRING "-_j_ 'lJ_ __" _ Q_

,SCREWS q '

/ SPRINGIDLE MIXTURE

. SCREW MT-_53_

Mr.153._

3: Carefully inspect the throttle valve for nicksorburrs and the throttle shaft for wear. Do notremove the throttle valve. If damage or wearis evident, the throttle body or carburetor mustbe replaced. If the idle mixture screw is bent orgrooved it must also be replaced. Correct idleadjustment cannot be achieved with agrooved or damaged idle mixture needle orscrew.

Page 461: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

3-12 "FUEL'.SYSTEM " 3-12-L .

HOLLEY 1940 ONE-BARREL CARBURETOR (Continued)_,

CLEANING ASSEMBLY

/i Carburetor.cleaning is thoroughlycovered in a . Exceptfor the following vacuum piston staking;previous section. During cleaning the bowl cover operation, and testing the pump discharge valve,

'.:, - should be placed on top of the other parts in the , reassembly is the reverse of disassembly. _,.basket with the main well tube projecting upward '- ._:_and protecte_l. It is apart of the bow!,cover,and NOTE: Before Installing the vacuum piston as-

sembly,be sure to remove all previous staking_,: cannotbe replaced Blowoutpassagesasshown._ from the retainer rec<_ss.Install the piston In ,,

,,_. ,_'._.i the vacuum cylinder and stake lightly with a _:i':;_ suitable tool.

:-!

j_ -':.w"

_ _ ( SPECIAL

• CAREFULLY POSITION ii':!.:;; AIRNOZZLE OVER" :: MAIN WELL TUBE:_ _ _ -

J

i

J PHI81

.j..:

Page 462: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" :3-13 "FUEL" SYSTEM . 3-13 ,., |

HOLLEY .1940.ON E-BARREl/CARBURETOR (Continued).

' Test, the pump-discharge valve prior to assem- Install the float shaft in _he float lever and insert

' thepumpblybyfilling the pumpcYdischargeball nder with clean fuel,HOldandweight down .with a ingaSSemblyinthe float shaft cradle.: Insert the retain-'spring. ,

small punch or drift and_operate the pump plunger Install a.newgasket onlthe new_fuel iniet valvei .by hand. If the valve andseat areJeakingfuelwill ,(needle: and seat). ,. . '., rise,around the,valve_,weight-and spill,over. . .. , , ,,

• Hold:the retaining ,sprjng.with,_the;_fingers and .... _.invert the,bowl:,A straight edge placed across the '

PRESSINGON., sudace'of.,the bowl _shou!d just.touch !the. toes .ofPUMP DISCHARGE, ,the float_._,(The:portion ,of'.theffloat,hangs farthest

BALL . -,from the_,fuel,..inlet.,),,l_,necessary:bend the float

-_ ,hang :,to,,obtain .this_ adjustment: ::Complete ,the 'reassembly. , '

• Y .... ,I._ . .... _,,_. _"

¢.."_ .... 'FLOAT ASSEMBLY

PUMPPISTON • .,:.,i _.!.

,"MT.15368

'ADJUSTMENTS. DURING ASSEMBLY/

Assemble, the throttle body. and .assemble the ..throttle body to the main body. Use a new gasketand torque the screws to 30 in-lbs, in three evensteps. Install the main jet and power valve with the

proper tools,

If the valve is leaking remove the hexagon

weight and lightly stake the seat with the old ballusing a suitable punch or drift_Throw the old ball STRAIGHTEDGEvalve away and install the new ballfrom the kit. atthe proper time during .reassembly.-.,

Page 463: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• " :4-01 CHARGING 401-IB

Part 4, Charging System*. _..

SUBJECT PAGE SUBJECT PAGE

• :DESCRIPTIONAND OPERATION REMOVAL"ANDINSTALLATION

Alternator................................... 4-01 Removal............. .......................... 4-13Regulator ..................................... 4-03 Installation ................................... 4-13Application: ................................... 4-03 ,. DISASSEMBLY:AND,ASSEMBLY

DIAGNOSIS .................................... 4-04 Disassembly...................................... 4-14TESTING Cleaningand:Inspection....... '................ 4-16

Battery ...................................... 4-05 Assembly ........................ : .................. 4-17ChargingSystemTests .ADJUSTMENTS.................................. 4-18

Motorola .................................. 4-06Motorcraft ................................. 4-07

Bench Tests ................................ 4-11

DESCRIPTION AND OPERATION

ALTERNATOR I

.... ._The_4;9.LiterEnginesuse elther_aMotorcraft ......current_,to_maintain:the,alternators.outputvoltage I•, , : ,:or:aMotorolaalternator. Most of this section , -,wthin prescrbed ,1mits_to;correctly,charge'.,the__,'"_,:,_.,applies ,to:the,Motorcraft .alternator, because . ,. battery.The.alternator,isself-currentlimiting.

the Motorola unit is serviced by Motorola.

The alternatoris belt driven from the engine. ThewarninglampcontrolcircuitpassescurrentCurrentis supplied from the alternator-regulator to thewarninglampwhenthe ignitionswitchis insystem to the rotating field of the alternator theRunpositiohandthereis noalternatorvoltagethrough two brushes and two slip rings, at terminal S. When thevoltage at S rises to a pre-

The alternator produces power in the form of set value, current is cut off to the warning lamp.alternating current. The alternating current is rec- This circuit is not included in the regulator fortiffed to direct current by six diodes. The alternator vehicles equipped with an ammeter rather thanregulator automaticallyadjusts, thealternator field_ the warning lamp.

Page 464: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-02 :,CCHARGING 4-02: '-_I

DESCRIPTION AND OPERATION (Continued) ,

• BATTERY:_,ERMINALOF STARTER'RELAY _ ACCESSORY' TERMINAL "-"-'-7"" CHARGE' GREEN RED STRIPE." ......... .. .. ...... . _ . • , I ,'INDICATOR

,, : _:, LAMP /

.- - BATTERY.i,, _,TCR _ _ , I "_"" . '' _;r_" FUSE LINK/ ( L. SO0 OHMS YELLOW I

(ORANGE) I" " I

WHITE "

BLACK ORANGE I

_-- ,-'.. ALTERNATOR._OOT'OTTERM,NALALTERNATORL//O I I ........ '_- _--1. --,,AT, t

'F

. ""._._._,.: DIODE RECTIFIERS S Ii I

' I WH,TEBLAC.STR,PE....I _::.....I" F

I- },__ -o' ..... I60 AMP A,, LTs I I

_,;, I fl _STATORW,NDING, I ELECTRON,_OLTAGEI' REGULATOR

:!:_:% , _1,,_L_,,9_,,I STATORTERM,_,AL L I

'_:'_' I ROTATING ..FIELD TERMINAL, I _ _k o__

' ':" I _ _ _ I ORANGE/LT. BLUE

_- "- _ __ JSLIP BtNC.S i_:

• J2227.2E

"7BATTERY TERMINALOF STARTER YELLOW/

WHITE tDOT

NOT USED I

WITH AMMETER IBATTERY FUSE LINK _=1(ORANGE) "o

BLAC_,ORANGE\ IALTERNATOR -- I

OUTPUT TERMINA AMMETER USED WITH I(BAT) SHUNT TYPE

i .,,j.AMMETER , _ . ,

ALTERNATOR --0--

I' TERMINALIGNIT ION I '_:_,

DIODE S Jl

RECTIFIER

IGNITION ISWITC H._..._'. GREEN/RED

':.; STRIPE I

F ILTS. I

I W,_D,NGS I E.CTRON,CVOLTAGE

I _ REGULATOR _ -_TERMINAL -_"m

• : ] STAI

.i I _ ROTATING I ./FIELD TERMINALI _ FIELD - _ I _ "_

I I "_oo-o-oyi--_o /_, L3_____J ORANGE/LTBLUE,, SLIP RINGS

J2228-2D

Page 465: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

- -4-03 CHARGING 4-03

• DESCRIPTION AND OPERATION (Continued)_.

.. A 500 ohm, 1/4 watt resistor is connected across, warning, lamp or through terminal Son vehicles

.:.,. - .:. : theterminalsof thelamp atthe instrument cluster.. .-equipped.with an ammeter:-With.aninput voltage -

in vehicles equipped with. an indicator Warning present; the switching .circuit turns on the voltagelamp. controt, circuit; which -in; turn controls :the output

' ' The Switching circuit receives voltage from the circuit.When the ignition switch is Off, the output• ' "ignition switch through the warning lamp control circuit remains open and no.current flows to the

circuiton vehicles equipped with an indicator alternator field. !

REGULATOR ...... .the:connector will not'index with the regulator• terminals'whenthe;wrong:regulator is inad-

• ._:The electrical!;charging _systems-incorporate a • " vertentlyinStalled in the'vehicle.,_;. newelectronicvoltage, regulator.. These reg- TO,_,_rE,,,O

" ulators are 100 percent solid state, consisting of ,_Nrr_ONASW,TC.

transistors, diodes, and resistors. The working _ "TERN^TOR

functions are .achieved using electronic compo- V _ 'T_ii__i'_:_lnents.arranged in basically three circuit divisions -

. as follows:,the output stage, the voltage stage,., . i-_c.. _%"c.I .

and the solid state relay. _ i .".!i!_.._•The new regulator will be :released under two .._ =.-._O,_N-,_O./'/" .,

.-.: separatepartnumberswithcolorcodes. Theunits' '_.j_"_,__', _will look alike,but are not interchangeable with the w,,_s_.____:_............_,r/ ! I _-:"{

' new regulator wiring harness connectorplugS.equipped an on _AwEt_,_ e., __ _ _'_

One of. these .units will. beused .on vehicles, .with ammeter,the other vehicles

equippedwith an alternator warning indicator , ,-r .'. G_u,o. -' RELAY .._, N

lamp. The regulators are calibrated and preset bythe manufacturer. No. readjustment is required or TO_o_o,,,O,:^ToRO,,,,_S,STO,L,_p

,I4.11ERNTOR

possible on these units. _ ST^,I-_._The new solid state regulators being used in _ ;.....................................................[_',._o_ ,._

conjunction with other new components in the I :_ "''F'ELD'_.'_'iJ/

charging system that must be properly matched to _l ELEC'rRON,CREGULATOR_" I .....GRO_'I"prevent damage to the charging system are as _ i I |follows: A-_ ///--_ " =_s_ /

1. A new alternator with higher fieldcurrentrequirement, ___ ._

2. A new warning indicator.lampshunt resistor.-

3. The alternator to regulator wiring harness is GROUND

changed to incorporate a new regulator con- 't _,=E,V""nector plug. The new plug is designed so that ST^,TER_TO" ....

RELAY I

APPLICATION on the new system wiring harness will notindex properly with the electro-mechanical

Whenever the system components are being regulator.replaced, the following precautions should be fol- 3. The electronic regulators are color coded forlowed so that the charging system will work prop- proper installation. Always use the black colorerly and components will not be damaged, coded regulator in systems which use the

warning lamp indicator. The blue color coded1. Always use the proper alternator in the sys- regulators must be used in ammeter gaugetem being serviced. Older model alternators, if

used in the present system, will have a slightly systems.reduced output. 4. The charging system uses a 500 ohm resistor

on the back of the instrument cluster on units2. Never use an electro-mechanical regulator in with a warning indicator lamp. Do not replace

the new charging system. The connector plug this item with the 15 ohm resistance wire.

Page 466: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:4-04 •CHARGING 4-04

DIAGNOSIS

.Troubleshootingor,diagnosisis,requiredbefore , the partof 'thesystem-causing,thesymptom."

:, ,..actual,:repairs,can,be.made inthe electrical,sys-,-., ,Next. visuallyinspectas follows:.: tem. Even_:wherean obvious fault makes the re- " ''" ' placement:ofa unit necessary, you must still find 1. Check battery posts and battery cable termi-

, out why the unit failed. When a trouble is diag- nals for clean and tight connections. Remove . ._,:.:. ..... nosed correctly, unnecessary repairs are pre- the battery cables (if corroded), clean and,_: .vented, the:timethe,engine is out oPservice_willbe install them securely.

..... decreased, and the repairs that are made will be 2. Check for clean and tight wiring connections _ ..... !_"-; permanent; at the alternator, regulator and engine. In- ,. ÷,.': Before_';performingcharging or starting system spect for evidence of arcing._ tests onithe engine, note the complaint such as:

slow cranking, battery dead or using an excessive 3. Check the alternator belt tension using belttensiongauge T63L-8620-A, Modg1210019or

.... amount !0f-water, top of battery wet, ammeter equivalent and tighten to specification (if.; ,.:_ shows charge at all times or no charge, alternator -,_"_ warning'lamp doesnot come on or never goesout, necessary)... -';_,. ._,,

.. voltmeter shows above or below open circuit nom-inal voltage. This information will aid in isolating

NORMAL CHARGE INDICATOR LIGHTwiringplugto the negativebattery postcable

With ignitionswitchoff.., alternatorlightisoff. clamp.

. With i_dition switch on (engine not run- 2. If the charge indicator light does not go on, :_._,• • ning) .... _alternatorlight is on. check the bulb for continuity and replace (if ..,_:,_

burned out)......i ._,:Wit.h..'.ignition_ swi,tch_.,_.o,q_,:(e,nginerun-ning).., alternator light is off. 3. If the bulb is not burned out, an open circuit

1. If the charge indicator light does not come on exists between the ignition switch and the _with the ignitionkey in the On position and the regulator. __'_engine not running, disconnect the wiring plug 4. Check the 500 ohm resistor across the chargeconnector at the regulator and connect a indicator lamp. Engines equipped with an am-jumper wire from the I terminal of the regulator meter will not have a resistor.

NORMAL CHARGE AMMETER _:_:_turns toward center scale in twd_':_steps(fully

With ignition switch off and no electrical chargedbattery).

load.., ammeter shouldshow0 or centerscale. ';With ignitionswitchoff and lightson... am-With ignition switch on and engine run- meter should show between 0 and discharge....

n!ng.., needle deflectstowardscharge andre- scale.

ISOLATING THE PROBLEM

- Battery, starting system, and light systems circuits to correctly identify the area where the _;problems can be caused by poor charging system difficulty lies. The best method to do this is to

:performance. It is also possible to suspect the checkthe battery first before any electrical system.; charging system because of an overload in an- diagnosis.The battery must be in the proper state ...:_._therarea of the electrical system. , of charge. The battery must be operating properly

" • To avoid guesswork, it is necessary to isolate before the other areasof the electrical systemcan_thebattery, the chargingsystem,andtheelectrical perform normally.

Page 467: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

-_4-05 CHARGING' 4-05

TESTING

: BATTERY" BATTERYDISCHARGERATES

Ampere Dlscl_argeRate" WARNING: KEEP BATTERIES OUTOF REACH: Hours Amperes

. -OF CHILDREN.,.BAT.TERIES.CO.NTAIN SUL- .45 •190" . '" ',FURIC ACID; ,AVOID ,CONTACT ,WITH . SKIN;: ..... ,, .53 ' ' 2oO."

. , . ,'.. _.,.'..EYES OR:CLOTHING;"ALSO,, SHIELD YOUR:" :..... "- 63 ' 260 '• '; .,:-EYES WHEN WORKING NEARTHEBATTERY ....... _;, r ::_,

• ' TO PROTECT AGAINST POSSIBLE SPLASH ........... :66 ' ' : ..... ' = '235 :..... -.ING" OF' THE ACID .SOLUTIONS,IN 'CASE.,OF_ - .... 7i.. 235.. ....' .ACID,,'CONTACT. WITH, SKIN, .EY.ES,.OR .......... 85 240

;CLOTHING;.FLUSH IMMEDIATELY WITH .........' ....9o. . ...... 310', .... WATER FOR .A'MINIMUM OF 15 MINUTES. IF " "

.... ACID IS SWALLOWED,_DRINK LARGE QUAN-. .": ":,TEMPERATURE.CORRECTIONCHART-"TITLES OF MILK.OR.WATER, FOLLOWED BY •......ALEBATTERIES

' ..MILK DE MAGNESIA', A.BEATEN EGGOR ..... Minimum Acceptable ,VEGETABLE • OIL.- CALL A PHYSICIAN , Temperature°F LoadVoltageIMMEDIATELY. 70(orabove) 9.6

60 9.5HYDROGEN AND OXYGEN GASES ARE PRO- .. 50 9.4 "

:DUCED DURING NORMAL BATTERY OPERA- ' v4o ,= 9.3' " TION. THIS.GAS' MIXTURE CAN EXPLODE IF " 3o .9.1

FLAMES, SPARKS OR LIGHTED TOBACCO : "20' ' s.9"...... :AREBROUGHT NEAR THE .BATTERY. WHEN to 8.7' !,_ :CHARGING ORUSING A'BATTERY/NANEN- ........ 0 .;8.5 '

,CLOSED .SPACE, .ALWAYS .PROVIDE

.... ,.. ' :VENTILATION.AND_SHIELD YOUREYES. _. .The battery..capacity:test.should_be run next to' remove"any ,surface charge pdor to determining.'..' .:.. :,BATTERIES'ARE'rHEAVY,/WEIGHING:30 "LBs. _:- ".

.... _OR :.MORE;: LIFT'THEMr_ WlTH,..YOUR'LEGS ,.: state"ofrcharge of"amaintenan'ce_fr.ee batteryl ,

rRATHER THAN YOURBACK"TO PREVENT :....CAPACI-_V'TEC_T_,I,,_.I,.'.,.!:..•,,., ...," :L ,':': ,.., _'.:.;" ":;!:'_._i:'.MUSCLESTRAINS; AND'BE CAREFUL NOT.

TO DROP THEM (POSSIBLE BREAKAGE) A high rate discharge tester in conjunction withNOR TO SPILL THE CONTENTS (SULFURIC a voltmeter is used for this test.ACID).

1. Turn the control knob on the Battery-StarterCAUTION: 12-volt starting motors can be Tester to the Off position.damaged beyond repair if connected to a 24-volt power supply (two 12-volt batteries in se- 2. Turn the voltmeter selector switch to the 20-ries, or a 24-volt motor-generator set), even volt position and test selectorswitch to"AMP."

when cranking loads are relatively light. Ex- 3. Connect both positive test leads to thetensive starting motor damageismore•likely if. positive ( + ) battery post and both .negativethe starter is connected to. a 24-volt .supply leads to the negative (-) battery post. Thewhile being subjected .to prolonged, heavy, voltmeter clips must contact the battery postscranking loads such as attempting to start an and not the high-rate discharge tester clips.engine in subzero temperatures. Unless this is done, the actual battery terminal

voltage will not be indicated.Tests are made on a battery to determine the

state of charge and also its capacity or ability to 4. Turn the load control knob in a clockwise di-crank an engine. The ultimate result of these tests rection until the ammeter reaches the applica-

ble discharge rate specified in the dischargeis to show that the battery is good, needs recharg-ing, or must be replaced, rate table.

Before attempting to test a battery, it is impor- 5. With the ammeter reading the required 10adtant to give it a thorough examination to determine for 15 seconds, note the voltmeter reading.if it has been damaged. Remove battery cable Avoid leaving the high discharge load on theclamps, negative ( - )terminal first. Check for dirty battery for periods longer than 15 seconds.or corroded connections and loose battery posts. If the voltmeter reading is above the mini-Remove holddowns and heat shields and inspect mum specified in the table with the test equip-for broken or cracked case or cover. If worn or ment for that temperature, the. battery has.a .damaged, loose or broken post, or cracked case good output capacity and will readily accept aor cover, replace battery, charge, if required. Check the state of charge.

Page 468: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'4-06 ,.:CHARGING.- . 4-06._..,Jl II

TESTING (Continued)

STATE OF.CHARGE w MAINTENANCE- Test'2 -- Ignition On --

, FREEBAT3"ERIES Engine Not Running'.:,'_,. :;|_:',., Read the battery open circuit terminal voltage The voltage regulator may be bypassed with a

': ,.;-;ii/"i_"with_adigital_voltr_eter capable of reading 1/100 of short jumper between the regulator and field ter-, : ":,._,|i,-_'a 'y0"lt.If the,10pe'ncircuit voltage of the battery is minals. If jumper provides approximate correct ,,_'_

/;::!,.be!0w 12.40:Y01tsand the battery has passed the voltage, fault is in the regulator. No change from _' _,_:'.... i=ii'_:;_/i_,_:capacity"_ tesL charge the battery.. " high voltage indicates that the defect is in the ;_:r_i, :: i ./: . ,, brush or rotor circuit.

'.i," ", , _ . - L: YELLOW "i'_

!!::ii:;i :'_:':_CHARGINg.S"YSTEM TESTS i pREENs--="!RE

i;:_!i.':I'iMOTOROLAI":_:'.:_

ion, engine output regulator connec-tion'smaintained to the alternator except as noted

.in Tests 3 and 5.,.The field lead and voltage reg- E• " _:_ ' OC VOLTS,,_.ulatorare disconnected for these tests,

:,;£AUTION: ': ' _':

• ,-.,_DO NOT'disconnect alternator output leadI'_`, ....... i. _while, alternator s operating. Test 3 w Field Draw Test _ Ignition Off

• ; .... ...... iD.O NOT.disconnect voltage regulator while This test evaluates comp(ete field circuit, inde-

iiI ,:,,; 'alternat0'ir is operating, pendent of voltage regulator. Circuit is through_, ,i,.._!DO NOT_ground field terminal, brushes, slip rings, field coil to ground. Current.',.,'-_Check battery ,condition. Use a fu ly should be 2 to 2.5 amps. If less than this. check ' ;

;.,.:_:',.,,_,.,::charged.battery when testing alternator: brushes and slip rings. It is desirable to use a field•,_,': '..:E:-:D sconnect :ground Cable_"bf::_bdttery!_when rheostat in series with meter for protection of the

.... removing and Installing the alternator, meter. If field is shorted, excessive current would

All readings indicated are for correct operation, flow through meter and possible damage would ,',.:_result.Test 1 _ Ignition On _ Engine Not Running ,,

Correct voltage at regulator: terminal is approx-imate;y 1.5 to 2.5 volts. This test evaluatesexcitation circuit.

If voltage at regulator terminal is:

5.0 to 7.0 volts = open rotor (field circuiti" _: ,_o:.....75 to 1.1 volts = grounded rotor circuit YELLOW _'_'....

8,5 to 10.0 volts = open in regulator's load IGN_ , ""

GREEN FLD WIRE0 volts = open ignition switch or excitation DISCONNECTED

resistor ' =

If test results are uncertain, gotoTest2. I _ _R B

IGN _ _ _ I"_'_

", .-

Page 469: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-07 CHARGING 407I II II

TESTING (Continued)

•.,.,TestA,-- Ignition Onto Engine Running at, MOTORCRAFT•,:: Fast Idle.

• Voltage indicated is usually 13.9 to, 14.7 volts When pefform!ng charging system tests with a'dependingon_regulator ambient temperaturel voltmeter, turn off all lights and electrical

•'"High voltage maybedue.to a poorgroundconnec-, components ....:. , .. tion.if ground•connection isnot faulty, regulator . CAUTION:.Be,surefield.terminalc0nnectoris

' will require replacement. , • installed on,the "Field'!,terminalStud atalter-' . nator_and,,not.the ground stud. •

................ IGN _ YELLOW.... I_'1"_'_-I ' _:Always'disconnect.:_the connector plug from

:,:,put :with, test,.probed, or" a ;jumper,wire.

i_ - Always:disconnect :_the,connector plug from• the regulator before _removing.the regulator-. mounting screws._Removing the connector

from an un-grounded regulator with the igni-

IA tion switch on will destroy the regulator.oc VOLTS .... _ .... Neverattemptto:polarizeor:test the alternatorby grounding :the:field:circuit;:as this .will de-stroy, the:regulator.

............................. Base ,Voltage ..Test _r"' , :-,,Test.5'--. FieldTerm -Disconnected 1: ,With-ignition off ,'and :_no.electrical' load on,

-._,Voltage RegulatorPlugDIsconnected, ' ' ':connect-the negative, leadof'the voltmeter to- ,. _,. , .::: Battery:Terminal Shortedto Field Terminal ..... --the negativebattery:cable:clamp. '

,.. ,- , Ignitlon,On--,Engine. Runningat Idle -..2! : Connect_the.positi_;e.leadof the voltmeter to.: - : : , ,..:;.This,test.isolates defect'to=either the alternator ..:'. ' thepositive battery:cable _clamp,:ii. .....

.or regulator. If voltage at auxiliary terminal rises to . 3. Record the battery Voltage reading shown on15-16 volts now. when it did not in Test 4 with the voltmeter scale (base voltage).regulator connected, then defect is in regulatorand it should be replaced. If voltage does not rise No Load Test

at auxiliary terminal, defect is in alternator stator or 1. Connect a tachometer to the engine.rectifier diodes, if field circuit checked out prop-erly. For defects in stator or diodes, remove 2. Start the engine and increase speed to ap-alternator, proximately 1500 RPM. With no other elec-

trical load. the voltmeter pointer should moveYELLOW upward (increase), but not more than 2 volts

IGN¢ --' _'_ E'_'I above the base voltage (first recorded battery

I r_ I_"E_(; I • voltage reading above). The reading shouldGREEN_"_'FLDWIRE _, i_,, _-• GREENDISCONNECTED' be taken when the voltmeter pointer stops

__A rising. It may take a few minutes to reach this

point. If the voltage increases to proper level,

performLoadTest.If thepointercontinuesto

rise, perform the Over Voltage Tests. If thevoltage does not rise to proper level, perform

+ R_I .J- the Under Voltage Tests.DC VOLTS TrE ' I

Page 470: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-08: :CHARGING : " 4-08 ',. .II I I I I • I I II I _., ,-.

TESTING (Continued)

GENERAL CHARGING SYSTEM TEST ....

'_ I PRELIMINARY CHECKS I

• BATTERY TERMINALS ANO CABLE CLAMPS• WIRING CONNECTIONS AT ALTERNATOR, REGULATOR AND ENGINE

_ TO BODY GROUNOS

• ALTERNATOR BELT TENSION •I

BASEVOLTAGE II

" -i:: • CONNECT VOLTMETER TO BATTERY POSTS. READ BATTERY VOLTAGE -- .'4THIS IS BASE READING _._j-.

!

:_i_: NO-LOAD TEST I

L

' ! • START ENGINE -- RUN AT 1500 RPM WITH NO ELECTRICAL LOAD, VOLTAGEI " "

..¢ |

INCREASES MORE THAN 2.0 VOLTSNO INCREASE • INCREASE ENGINE SPEED TO 2000 RP.M I I

• TURN HEATER/A.C, BLOWER AND HEADLIGHTS ON HIGH | |• VOLTAGE SHOULD READ MINIMUM OF 1/2 VOLT |

OVER BASE VOLTAGE " II i OVER VOLTAGE TESTS

! LESS THAN 1:2 VOLT 1/2 VOLT OR MORE

t , I

' l I" UNDER VOLTAGE TESTS ALTERNATOR AND REG- CHECK GROUND ATI ULATOR ARE OK. PROBLEM REGULATOR WITH

CAN STILL BE BATTERY JUMPER WIRE• DISCONNECT REGULATOR DRAIN. TURN OFF IGNITION.

• CHECK RESISTANCE BETWEEN "F" INSTALL TEST LIGHT IN | ' ITERMINAL OF REGULATOR SERIES WITH POE. BATTERY OVER VOLTAGE OVER VOLTAGECONNECTOR AND GROUND CABLE ANt:) CHECK TO DOES NOT GO AWAY GOES AWAY

• RESISTANCE SHOULO BE _F_E THAN 3 ISOLATE PROBLEM CIRUIT IFOHMS NO DRAIN, CHECK BATTERY L I .

-' CAPACITY. [ I• - I 1 ' DISCONNECT SERVICE GROUNDREGULATOR. SEE

.. LES S _THAN 3 OHMS MORE THAN 3 OHMS.. IF OVER VOLTAGEI " " :'1_ " ": ': _' " ' CONDITION GOES

I I AWAY.

SERVICE GROUNDED • JUMPER A TO "F" TERMINAL AT

FIELD CIRCUIT. NOTE: IF REGULATOR WIRING CONNECTOR !FIELD CIRCUIT IS • VOLTAGE SHOULD READ A MIN-GROUNDED REPLACE IMUM OF 1/2 VOLT OVER BASE I" 1REGULATOR ALSO. READING. WITH LOAD TEST CON. OVER VOLTAGE OVER VOLTAGE

DITIIONS IN EFFECT [X)ES NOT GO AWAY GOES AWAY

• I I

,i I ALTERNATORANDREGULATOR, ALSOLESS THAN 1/2 VOLT 1/2 VOLT OR MORE REPLACE REGULATOR.

I SHUT OFF ALL LOADI!

REMOVE JUMPER FROM "A" VEHICLES WITH VEHICLI_S WITHAND "F" TERMINALS BUT ALTERNATOR WARNING LIGHT AMMETERLEAVE REGULATOR OISCON- t -NECTED. JUMPER "BAT" TO I

"FLD." TERMINALS AT ALTER- l ENGINE AT iDLE WITH JUMPER • ENGINE OFF --

NATOR. VOLTAGE SHOULD STILL ON TERMINALS "A" AND • IGNITION SWITCH ONREAD A MINIMUM OF 1/2 VOLT "1_ CHECK FOR POWER TO • CHECK FOR POWEROVEF_ BASE READING WIT_ THE "S" AND "r TERMINALS TO "S" TERMINAL ONLOAD TEST CONDITIONS IN AT REGULATOR TERMINAL. REGULATOR CON- ,

. EFFECT. VOLTAGE AT THE "S" TERM -_" NECTOR.NAL SHOULD BE ABOUT I/2 OF'

; T THE VOLTAGE AT "I" I

1 I1

| I I { I J

LESS THAN 1/2 VOLT I12 VOLT OR MORE NOT OK OKi [ l I

STOP ENGINE. SERVICE OEFEC. SERVICE "S" REPLACEMK_/E POE. TIVE "A° OR "F" CIRCUIT (IGNITION REGULATORVOLTMETER LEAD CIRCUITS• SWITCH TO

" TOBAT.TERM•OF REGULATORALTERNATOR• CONNECTOR)•

i .. I !

I ' I NOT OK OK

BASEVOLTS ZEROVOLTS I , _

J ",, SERVICE DEFEC- REPLACE

SERVICE OR SERVICE BATT. TIVE "S" OR "T" REGULATOR " "REPLACE WIRE CIRCUITS

'ALTERNATOR

Page 471: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,4,.09 CHARGING 4-09II I II

TESTING (Continued)

Load,Test, regulator, Connect a jumper wire to the FLD

1. _With the engine, running,, turn the heater or air ,-.. and BAT terminals ,on the alternator and re-.conditioner blowermotor on'(high speed) and ,peat the Load Test. If the voltmeter now indi-.headlights on.high beam. cates 'more,, than 1/2.' volt' above the base

voltage,perform S and ,I.Circuit'Test. and ser-• .. 2., •inc:rease,the engine,.speed to. approx mately,. ,' _:._._vice,the,wiringharness from :the,alternatorto

• :2000 RPM. The,voltmeter should.indicate a ,the,regulator ......... , . ' ,, ,_.,minimum of O.5 volt above the base voltage. Ifnot, perform the UnderVoltage-Tests de- . 4. If.the .voltmeter:still_indicates-undervoltage,:scribed below. . . • :.. stop the_.engine:and move;the,positive volt:

• •if:the above tests.indicate proper voltage read- meter, lead ..to.the, alternator, ,BAT,.:terminal., :,.'ings.(t/2 volt:open'circuit:above base);thecharg-". _: 5.... ff, the:;,yoltmeter._now':indicatesitl_ebase volt- .

. ..: rag. system 'isoperating, normally: ,Proceed ,to'-the:- ,: ', : .age:readingiservicethe:alterna.tOr,.,, If the volt-,"-: .tests-,below if:one'or,' more,.of_,the,readings ' are" .:;/_.,:_.:meter:indicates,zero_.volts,,:serviCealternator

.,different, than shown above.and use a test/ight to : . to starter relay,wire.check for .battery drain,

A LOWER

• Over Voltage Tests READING METER SJ'_OULD INDICATE BETWEEN' INDICATES A ,4 AND 250 OHMS

.1. , If the voltmeter reading indicates more than. SHORTEOO,_GROUNDEO

2.0 volts above..base voltage,.,connect a '_.ELDCI,CU.T -" ----, jumperwire between the:regulator base and ,(INCLUDING........• ,IALTERNATOR) '' ,-' OHMM E_'ER

..... alternator frame. Repeat the No .Load test. If,, .,overvoltage,condition disappears, check ' '

., ground.connections on :alternator;:, regulator , ,.and, from 'engineto, firewall and to .'battery.

,. Clean. and, tighten .connections,securely. . .• _ ' ';SET'OHMMETER

. ::., "2: If.overvoltageconditionstill, exists, disconnect, h "" _.,"MULTIP"WBY_ , , , :.the •regulator •wiring. plug from the regulator', .. ,. 'KNOBAT ", and repeat the.No Load test. ... _, ,.. ,:. '/i._,_. '/, .,: :,_, "

3. If over voltage condition disappears (volt-.meter reads battery base voltage), replacevoltage regulator.

4. If over voltage still exists with the regulatorwiring plug disconnected, check for short be- '=tween "A" and "F" in the wiring harness plug TERMINALUSEBLADEand service as required. Replace the reg- BgA-V._._

FROM TERMINAL

ulator and connect the regulator wiring plug to K_TNO.B9A-14294.PAKIN REGULATOR PLUG.

the regulator.

Under Voltage Tests,

1. If the voltage does not indicate more than 1/2volt above base voltage, disconnect wiring J_633-_oplug from regulator and connect an ohmmeterfrom "F" terminal of plug to ground. Metershould indicate more than 2.4 ohms. If less Fthan 2.4 ohms is indicated, service groundedfield current in wire or alternator and repeat AsLoad Test above.

2. If ohmmeter indicates more than 2.4 ohmsconnect jumper wire from "A" to "F" terminalsof regulator plug. Repeat Load Test above. If.voltmeter now indicates more than 1/2 voltabove base voltage, service wiring to reg-

USE JUMPER WIREulator or regulator. TO CONNECT "'A'" AND "F'" TERMINALS

3. If the voltmeter still indicates under voltage, ATREGULATORPLUGremove the jumper wire from the regulator j_S-_Aplug and leave the plug disconnected from the

Page 472: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-10 ":_CHARGING _ 4-10• :,,_..- I I I _" :":'_ ' ":"

TESTING (Contlnued)

Regulator S and I Clrcult TestsS-Circuit with Ammeter

1. Connect the positive lead of the voltmeter tothe S terminal of the disconnected regulator

wiring plug and negative lead of voltmeter to _'!_

' battery ground terminal. Then, turn the igni- ' '_

,_ tion switch to the On position. DO NOT start

the engine. No voltage should be indicated ._._

• with ignition switch Off. _. !i!2. The voltmeter should indicate battery voltage. .

3. If there is no voltage reading, service the S ' ;wire lead from the ignition switch to the reg-ulatorwiringplug.

_:_IREARTERM,NAL 4. Connect the positive voltmelter lead to the,'_ALTERNATORS / JUMPER WIRE

... t CONNECTEOTOALTERNATOR positive battery cable termina'l, connect reg-', "BAT"ANO"'_LD"TERMINALS ulator wiring plug to regulator.and repeat the

.- LoadTest.

" S and I Circuit -- With Indicator Light

i' : _ / 1. Disconnect the regulator wiring plug and in- "'

'BAT' stall a jumper wire between the "A" and "F" ..FL0' terminals.

. _ 2. With the engine idling, connect the negative

' " 1_ voltmeter lead to the battery ground terminal

and the positive lead of the voltmeter to the Sterminal and then to the I,terminal of the reg- -ulator wiring plug. The voltage of the S circuit _ . i

_O_RENRM_oA_ should read approximately one-half of the Icircuit. __

3. If no voltage is present, service the wiringcircuit. Reconnect the positive voltmeter lead

JUMPERWtRECON,ECTEO to the positive battery cable terminal.- F'**'**--_ TO ALTERNATOR

REGULATORPLUG _ "BAT"AND"FLO"TERMINALS 4. Then, remove the jumper wire from the reg-REMOVEO_ ulator wiring plug and connect the wiring plugFROMREGULATOR J_636-,E to the regulator. Repeat the Load Test.

Page 473: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• 4-11 CHARGING ,411 "• I | '

TESTING (Continued)• i

BENCH:TESTS 2. Perform the same test using the STA and• • GND terminals. A.readingin' both.directions-.-.-

" " " " After. the general .charging system diagnosis- ,indicates,either a grounded.stator winding, ahas isolatedthe problem to thealternator, remove, badnegativediode,.a,grounded stator termi-:it fromthevehicle for bench testingand service,or nal,_a. grounded positive diode .plate, or a

,..replacement: Refer.toAlternator Removaloand '.' groundedBAT terminal_' ' D!sassembly in this section. . • • .-

3. If.there ,is,,no..need!e,.movement with the.-, Rectifier Short or.Grounded and.Stator.-.,, • probesJnone.direction and'a:.high',resistance

.Grounded Test • . ..(sigqificantly.over/6,ohms)-in_theoppos te di-" .'.These,tests.are .performed with. anohmmeter .... ,. rect on,_f0reither,test;abad connection exists

' (Rotunda50-0010or equivalent):Set the "Multiply _betwe.en;,the;;stator,.lead:terminal. andtheBy, knob at :1.and,..calibrate .the.ohmmeter as. stator:bolt.head.

directed. Field Open.or Short Circuit Test

, CAUTION: Digitai_meters cannot be used to. This test is performed with an ohmmeter. Setperform these rectifier tests, theohmmeter"MultiplyBy"knobat1andcalibrate

•. 1. Contact one ohmmeter probe to the alternator the ohmmeter as directed inside the instrumentBATterminal(terminalwith red insulator)and cover.

. ' the'otherProbe to the STA terminal (terminal -1. Contactthelalternatorl field terminal with one_with black•insulator).Then , reversethe ohm- . ..... probeand the ground:termir_al.withthe other

. .meter probes and ..repeat the test..Normally .... probe.:Then,;spin:.the"alternator .pulley. Thethere:will:beno-needle movement in one di- . .......... ohmmeterreading should be between2.4 and

• rection, indicating_the•.rectifier,diodes are .lO0ohmsand'should/fluctuate.while thebeingchecked in the reverse currentdirection

.;and.are not shorted. Alow reading.with the ' pulley is turning.. . ...... probes:reversed indicates, that •rectifier .. ;2. ,. An infinite reading,(nometer movement).indi- .

: , . positive diodes:are being:checked in the:for...... .,_cates.:an-open.,brush..lead;worn_or stuck....,.wardcurrent,direction., Using -the referenced brushes,or a bad:'r0toriassembly:;' _,Ji- :.__,i:!_,:_: :._:•_ tester, the low reading should be about 6 3. An ohmmeter reading less than 2.4 ohms indi-

ohms but may vary if another type oftester is cates a grounded brush assembly, aused. A reading in both directions indicates a grounded field terminal or a bad rotor.bad positive diode, a grounded positive diodeplate or a grounded BAT terminal.

e 11 I_.E--'--_, ,--'_1 I INSU'LATOR k INSULATOR

_HMMET_R _MM ETER ///_ e _ (_ _

Page 474: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

....•4-12 " ;-:CHARGING. 4-12-

TESTING (Continued)

Diode Test Be sure that the probe makes a good elec-' ,,_Remove:.the:rectifier:assemblyfrom:the_:alter-:__,,- . trical connectionwith,the stator core: The ' ,'

,, nator.Set the ohmmeter"MultiplyBy" knobat 1 meter should show an infinite reading (no "and calibratethe meter as directed, meter movement).

',.-, CAUTIO'N: Digital meters cannot be used to 2. Ifthemeterdoes not indicatean infiniteread- "perform",!hesediode tests, ing (needle moves), the stator winding is _;-1. Tote_ onesetofdiodes,contactOneprobeto shortedto the core and must be replaced.

thete_'minalbolt and contact each of the three 3. Repeat this test for each of the stator leads. __ _'_stator_leadterminals with the other probe. Re- Do not touch the metal probes or stator leads

_ verse_theprobes and repeat the test. All di- with the hands. Such contact wilt result in anodes,',;,,shouldshow a low reading of about 6 incorrect reading.

ohm_'_inone direction and an infinite reading StatorCoil Open Test ""(no needle movement) with the probes re-

ii:t:_ versed. The low reading may vary with the This test determines if there isa_i0pen stator _type of tester used. This reading may be circuit.Disconnectthe statorfrom the rectifieras-checked against a good rectifier if it is sembly.Set theohmmeter"MultiplyBy"knobat 1.

-: available. 1. Connect one ohmmeter probe to a stator_:'_., phase lead and touch the other probe to an-_ other stator lead. Check the meter reading.

'_ :_!_ OHMMETER

' _- E.S

OHMMETER

I_ONTA_TE__

TERMINAL J3153 1A

2. Repeat theprecedingtestsforthe othersetof, diodes except that the other terminal screw is -_:_i_

used.TATOR

3. If the meter readings are not as specified,

: replace the rectifier assembly. ,._>_

. Stator Coil Grounded Test... J2583-IC

These tests are made to determine if the statorcoil is operating properly. Remove the stator from

.the alternator and disconnect from the rectifier. assembly (refer to Disassembly procedure in thissection). Set the ohmmeter "Multiply By" knob at 2. Repeat this test with the other two stator lead

1000. combinations. If no meter movement occurs(infinite resistance) on a lead paired with el-

1. Connect the ohmmeter probes to one of the ther of the other two leads, that phase is open..... stator leads and to the stator laminated core. and the stator should be replaced.

Page 475: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

. '" " '4-13 CHARGING .• 4-13

TESTING (Continued)

,_ -Rotor Open or Short Circuit Test

, :,Removethe,_rotor from:the alternator."Set the 4. Contact one ohrnmeter probe to aslip ringand _," .... " ohmmeter "Multiply By"_knobat 1and calibrate the the other probe to' the rotorshaft. The meter"

meter as directed, reading should be:infinite (no deflection).

.,., .1:,. Contact eachohmmeter probe to a rotor slip, 5. Areadingotherthaninfiniteindicates therotorring.The meter reading shouldbe 2.0,to 3.5 is,shorted to the shaft. Inspect the. slip ring ,ohms. soldered, terminals _to be _sure they are not

bent'and,not,touching the rotor shaftor that.2. Amhigher _reading indicates.a damaged slip .excess_solder is'not grounding'.the rotor shaft• .ring solderconnectionor a,broken wire.. - •

; or,that excess:solder is!nqt grounding the rotor..... [ ' 3. _A Iower_reading:indicates a shortedwire or_..... coilconnections :to the shaft.:Replace the ro-

,, .,..slipring: Replace the rotor if it is damaged and ,,,: tot' if:,itis:.shorted :and :cannot be_serviced.' cannot be serviced. ,..

REMOVAL ANDINSTALLATION

• .,.WARNING:. HYDROGEN AND, O.XYGEN OF, MILKOR;WATER;,FOLLOWED:B_.MILKOF: ':GASES,,ARE PRODUCED.,DURING,NORMAL, " MAGNESlA;;A:BEATEN:EGG;.,OR VEGETABLE' _BATTERYOPERATION., THISGAS: MIXTURE ' ,.OIL, CALL'.I,A:;PHYSlCIANtMMEDIATELY ....

:: CAN"EXPLODE:IF FLAMES/SPARKS OR' LIGHTED:TOBACCO ARE:BROUGHT NEAR REMOVAL

• ' ',:THEBATTERY'.WHEN;CHARGINGORUSlNG

• ,. :A _BA'r3"ERY =IN AN ENCLOSED.SPACE,.AL- . 1.,•' Disconnect the ground cable!from the battery.

WAYS PROVIDE,VENTILATION AND.:SHIELD . 2. ,_Loosen.the:alternator,pivot.,bolt.and.removeYOUR,EYES. • the adjustment, arm,to-alternator_bolt..

_: WARNING:KEEP OUT.OF, REACH OF CHIL-,. 3. Disengage the!alternat0rdriVe;belt fi'smthe.... .DREN. BATTERIES'CONTAIN SULFURIC drive pulley.

ACID. AVOID CONTACT WITH SKIN, EYES OR.CLOTHING. ALSO, SHIELD YOUR EYES 4. Disconnect the wiring terminals from the back .WHEN WORKING NEAR THE BATTERY TO of the alternator. The stator and field wiring_PROTECT AGAINST POSSIBLE SPLASHING terminals are the push-on type. The push-onOF THE ACID SOLUTION. IN CASE OF ACID type terminal should be pulled straight off theCONTACT WITH SKIN, EYES, OR CLOTHING, terminal to prevent damage.

FLUSH IMMEDIATELY WITH WATER FOR A 5. Remove the alternator pivot bolt.MINIMUM OF FIFTEEN MINUTES. IF ACID ISSWALLOWED, DRINK•LARGE, QUANTITIES , 6. Remove the alternator.

INSTALLATION NUT-383_56.S36 w_s.E,-380097.s3668-10.'1 Nm _ t \

(60-90 ,N-L8$] "_ /

1. Position the alternator on the engine.

2. Install the alternator pivot bolt and adjuster ' BoL'r,s_6r_.s36bolt. 88.78N-m

{48-58 FT-LBS|

3. Connect the wiring terminals to the back of thealternator.

4. Install the drive belt over the alternator drivepulley.

5. Adjust the belt to specification.

6. Connect ground cable to battery. / _r=_-__l i

/ _=_'_"_'_ _WIRING ASSEMBLY-14305ALTERNATOR- 10300

J2550- IA

Page 476: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

..4-14 . -:":CHARGING,- 4-14 :_ ....,_ I _ I I, " ""_' "_ "

DISASSEMBLYAND ASSEMBLY 'j

.DISASSEMBLY 7. Remove the screws attacrting the brush hold-er to the rear housing..

. NOTE: All,of the following dlsassembly, steps'-._ .... 8. Remove the brush holder, the brushes and..... may not be necessary to perform a particular the brush terminal insulator from the rear

test or repair. Perform only those steps that housing. _,apply in your case.

9. Using a suitable arbor press, remove the.. ,The rear'terminal,alternatorwillhave one:of two bearing from the rear housing. Support the

types of rectifier assembly. One is a flat design housing close to the bearing boss to prevent .:,, with built-in..diodes. The other type is a stacked damage to the housing. _y

."' design with:!exposed diodes. Procedural steps af-fected by:;thle differences in the rectifiers will be 10. Clamp the front housing in a vise with protec .... , .

noted. _::,i_i tive jaws.• -.!.__ io.,:1 Scrlbe._a line across the end housings and 11. Remove the drive pulley retaining,_ut from the

.._:. stator.fframe for: alignment reference during rotor shaft using Removal/Instaii_ation Tool,assembly. T65P-10300-Bor equivalent.

2. Remove the three housing through bolts. 12. Remove the Iockwasher, drive pulley, fan andfan spacer from the rotor shaft.3. Separate the front housing and rotor assem-

, bly from the stator and rear housing assem- 13. Remove the rotor from the front housing andbly. It!._may be necessary to tap the front remove the housing from the vise.housing with a plastic tipped hammer to 14. Remove the front bearing spacer from theIoosen'.the front housing from thestator frame. rotor shaft. Do not remove the stop ring from

4. Remove the brush springs from the brush the rotor shaft unless it is damaged.holder in the rear housing.

:_: 15. Remove the screws attaching the bearing re-5. Remqye the nuts, washers and insulators tainer to the front housing and remove the

from the terminals on the back of the rear retainer.housin_ • Note the color and .location. of the

.... insulators for assembly :_'_f_i-__c:e_,'':;_ --_, 16. Remove the bearing from the front housing. Ifthe bearing will not slide out, remove it using a6. Remove the stator and rectifier assembly from suitable arbor press. Support the housing

the rear housing, closeto the bearingboss to preventdamageto the housing•

RADIO NOISE P,AO_O NO*,SE

BATTERY TERMINAL SUPPRESSION BATrERY SUPPRESSION RECTIFIERINSULATOR CAPACITOR STATOR TERMINAL CAPACITOR ASSEMBLY(ON TOP OF / TERMINAL " INSULATOR t / _D_OMNO,T 'CAPAC, OR / /INSULATOR \ | /EYeleT, / SO,ARESTATORX / /

L,_::==I_ _ -- _ RECTIFIER 'VI_1 f_ [ _ [=r%.

i _STATOR ::1

',PHASE • INSULATIt_G WASHER _ ST'_ATORLEAD STATOR PHASE

W_NOING LEADS FLAT TYPE (INTEGRATED) LEAD -- ...

RECTIFIER WITH EXPOSED DIODES RECTIFIER

(DISCRETE)

STATOR AND RECTIFIER ASSEMBLIES J224S-2D

. £,: :,

Page 477: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,4-15 CHARGING._ 4-15I I II

DISASSEMBLY AND ASSEMBLY (Continued),- ,.

RECTIFIER ASSEMBLYREAR HOUSING 10304

110334

STATOR FRONT HOUSING10336

/ ROTOR 1,C_33

/ /REAR BEARING / / FRONT BEARING " ,"/ • .... ' ;: " ' .....

10A304 _ BRUSH TERMINAL i / . . 10094 , ,,/

_P_:=I_ 3,9251sa .j, gog RE0,2,NER/ _, .,:;_ ._,,p.._r . 10328 '_ I " . ,." PULLEY

, _- "_:. ql • ./ 10344

• ROTOR STOP " "I;:__INSULATORS _ . _l .. _ 103 7 , _r

THROUGH _ \ RADIO SUPPRESSIONBOLTS J BRUSH SPRINGS CAPACITOR

378466-S [ 10349 18827 , /_ , . 389767BRUSHHOLDER ....10351 SCREWS

' FAN SPACER379201-S . , , ,10A344

Jt 166-2Q

,..19:,,Disconnect ,the stator..,phase ,lead, from the.- 15/16 INCH SOCKET _'_ _ ,,,;'. rectifier-assembly: as,follows:.. •

\ _ _ , ,Flattype.(integrated):rectifier--,'Remove:the,TOOL , :stator.' terminal.:screwby,:p_essing,,it,straight,.o/• _,',,.out of the rectifier, Do not turn the terminalscrew during removal. Turning the screw dur-ing removal will destroy the serrations cut intothe rectifier to hold the terminal screw inposition.

Exposed diode(discrete) rectifier _ Removethe stator terminal screw by turning it 1/4 turnto unlock it from the rectifier assembly.

\\_3/4 INCHWRENCH_ I J2S77._A 20. If necessary, the ground terminal can be re-moved from the rectifier assembly by follow-

.. _ ,, ........ ing the appropriate procedur e outlined in Step19.

17. Remove the radio suppression capacitor andthe battery terminal insulator from the rectifierassembly.

ASSEMBLY

18. Using a 100 watt soldering iron. unsolder the / . 1o3o4stator leads from the rectifier assembly. Do ,/_ STATORnot allow the soldering iron to overheat the --_, _ _WINDING

_A DS

rectifier. When removing the rectifier assem- STATO

bly from the alternator, do not cut the stator TERM_

lead wires. Unsolder the stator terminals fromthe molded circuit board terminals and withneedle nose pliers pull stator lead terminalsupwards from the rectifier assembly. Whilethe terminals are still hot, shake the molten NEEDLENOSEPLIERsolder from the terminals. JZ232-tB

Page 478: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

,4-16 : :CHARGING"- 4-16 _

DISASSEMBLY ANDASSEMBLY (Continued),;,

"[ c,_, ^o¢ ¢',r.,,vr_a /_1 STATOR PHASE _ _ STATOR, o_v_,,= ,._._.v,, ,L _LEAO STATOR NEUTRAL| TERMINAL _f_ //" _'_ _, _'_ PHASE LEAD -- TERMINAL

/ INSULATOR .///_'_t_'_%_/_ //. -,_ _ _ - • _, , _ __ /• ' UNLOCK/ : _ IZ/_/_,-_X INSULATING // / {'L_ _.__._ _ _ ____._ _

/' sTAToRI{roll_l,: /'--II\V ,o_o, I1"1_"f II"%_I _'_J'..\_.........:o_;q"¢"

TERMINAL I "_ / 2_"

41, )))el0,,,,0' . | I _;l;." II "-"1/ _ _ _ II / v; (STEEL)

"i [ !'"-i'._"' _ . ' _(___ CTIFIER ASSEM 8_ II. _/'P__U GROUNDTERMINAL._iI(I_,,=_:,r._.' '

RECTIFIER

• -,LAT_P_,,.TEORATEO,REC_,F,E. ,O,S%'_,W,T.EXPOSE° Jt401-2L

I

i.. ;CLEANING AND INSPECTION place the bearing if these conditions exist, or if.,. ,.,,, the lubricant, is lost or contaminated.

'.,CAUTIONS. When rebuilding a high tem- 5. Check the pulley and fan for excessive: perature 60 AMP alternator, use only high looseness on the rotor shaft. Replace any

•_temperature rectifier assembly and bearings, pulley or fan that is loose or bent out of shape.Use of stahldard parts will result In alternatorfailure. .< 6. Check both the front and rear housing for .i_

" cracks, particularly in the webbed areas and" 1. "Wipe the rotor, stator 'and,bi_arin_ls*With a at the mounting ear. Replace damaged or,- clean cloth. Do not clean these parts with cracked housing. ,.solvent. !:_

7. Check all wire leads on both the stator and2. Rotate the front bearing on the drive end of the rotorassemblies for loose or broken soldered

rotor shaft. Check for any scraping noise, connections and for burned insulation. Re-looseness or roughness. Look for excessive solder poor connections. Replace parts thatlubricant leakage• If any of these conditions show signs of burned insulation.exist, replace the bearing.

3. Inspect the rotor shaft rear bearing surface for 8. Check the slip rings for nicks and surfaceroughness or severe chatter marks. Replace roughness. Nicks and scratches may be re-

moved by turning down the slip Nngs. Do notthe rotor assembly if the shaft is not smooth, go beyond the minimum diamet'er._of31 mm

4. Place the rear bearing on the slip ring end of (1.22 inches). If the rings are badlydamaged,the rotor shaft and rotate the bearing. Make replace the rotor assembly.

the same check for noise, looseness, or 9., Replace the brushes if they are worn shorter, roughness as was made for the front bearing. :':i!::'than6.35 mm (1/4 inch). ..........

_,. Inspect the rollers and cage for damage. Re-

"T

' ,_F'

Page 479: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-17 CHARGING 4-17IBll

• ,DISASSEMBLYAND ASSEMBLY (Continued).

ASSEMBLYPRE_,S FIRMLY AGAINST HOUSING

' "•':""' '" ..... .2."1."'Install:thebearingontheposition.OUtertheraCebearing:'intheonly:.retainerfrOnt,,h°using:on,the Press,•front i '" ,ii_:__. ,.j__"" "' '" F_ "

housing and install the _attaching screws. ° :: !_ i _:._._.._._!

Tighten.the screws to 2.8-4.5 N.m (25-40 in- i..'..:_... (_ '

Ib):

',te oring.w sremove .,romro or"shaff, install anew ring by sliding it•over the . .

•end.of,the shaft,and into the groove, Do not .,,_,s.,;io_-'_ER:i

open,the ring with,snap ring pliers as,perma-, . _ ' __ _ _!:!!:.,.,_,,nent deformation of,the ring,wilL result ..... _,."h '_

'4. Install the bearing'spacer.on the"rotor,.shaft _._,;_,:._,_ ,--_' _ j.with the recessed,slide against the stop ring. ..... . J _ ,

5. Install the rotor in the front housing and clamp _!;_:_:_.:- ,._"_ _.; .....• J_2o6,_• : _ " ". .._ll_lee_ •

the housing in a vise.

•6._Install,the fan spacer, fan; drive pulley lock- 11. Positionthebrush'h0tderinitherear housing, " washer and nut on the rotor shaft. Tighten the ,, and_install ,the,attaching,screws. Tighten the

. nut to 82-135 N.m _(60-100 ft-lb)•using 'Re- ' ..... screws,to 1,9-2:8 N.m(17-25ff'-Ib). P_ess the.. ,moval/InstallationTool, T65P-10300-B or .... brush:holder firm!yagainst,thehousing while

equivalent.., :tightening ,!he screws:Make'sureithe:,ground•brush wiring eyelet_,is ..positioned .under the7: Removethe, rotofand housing assembly from .screw.before :tightening.the vise.

8: Support. the rear. housing, closeto thebearing ! _12..Connect' the stator, phase, lead to the ,rectifierboss to prevent damage to the housing and assembly as !ollo_s,!. _ _.,_.....,. _'..: ,:, .,i_:_.,:,,_',_.install the bearing using a suitable arbor Flat type (integrated) diode rectifier _ Posi-press. Press the bearing into the bore until it is tion the stator terminal insulator and the statorflush with the housing, phase lead on the rectifier assembly. Insert

the terminal screw and press into position.9. Position the brush wiring eyelet over the brush The screw should be pressed in far enough to

terminal and install the brush terminal keep the phase lead terminal from moving.insulator.Rectifier with exposed diodes (discrete)Position the stator phase lead and dished

___ washerontherectifierassembly, lnsertthe

GROUND t"

EYELET_ _f_ BRUSHHOLDER,, ..... terminal screw and lock into place by rotatingBRUS. . _0_s_ 1/4 turn.

13. If the ground terminal was removed from theSTIFF WIRE

/ BRUSH P_N rectifier assembly, it can be installed by press-

/,/_/HOLE SEAL ingprocedureOrturninginStepaSoutlined12,in the appropriate

14. Before soldering stator leads to rectifier, make

' _I II I BRUSH sure that the insulator sleeves are in place.,_ I I/,4.f_._.,_.TERM|NAL Wrap.the stator winding leads around the ter-

_ 379251.s minals of the rectifier assembly and solderthem, using a 100 watt soldering iron and resin\ BRUSH core electrical solder. Do not allow the solder-

_TERM|NAL

WIRING INSULATOR ing iron to overheat the rectifier assembly.EYELET 10329 Press the sleeves on the terminals before rec-

_=ST_._A tiller soldering.

15. Install the radio suppression capacitor and

10. Install the springs and brushes in the brush battery terminal insulator on. the rectifierholder. Hold the brushes against spring ten- assembly.sion by inserting a piece of stiff wire through 16. Install the insulator on the stator terminalthe brush holder, screw.

Page 480: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

4-18. ..,::CHARGING 4-18j.I IIII

• m ......

DISASSEMBLYAND ASSEMBLY ADJUSTMENTS

(Continued) DRIVE BELT

'17. Align the_terminalscrews on the"rectifier•as,_'_;.... The fandrivebeltshouldbeproperlyadjustedat -_,, sembly w!th the holesin the back of the rear all times. A loose drive belt can cause improper,:. _. housing.i_ndinstall the stator rectifierassem- alternator, fan and water pump operation. A belt

" bly in the!irearhousing.Make certainthe termi- that is too tight places a Severestrainon thewater :.!i_:., nal insulators are seated.in their recesses, pump and alternator bearings.,_!8. Install the external insulators,washers and A properlytensioned drive belt minimizes noise _';, nuts on.the terminals.The insulatorsare color, and also prolongs the service life of the belt. "'_;.:._• coded a_'_follows: Therefore,it is recommendedthat a belt tension

_:_... gauge be used to check and adjust the belt ten-:i.. Black on::_thestator (STA) terminal. Tighten sion. Any belt that has been operated for a

": nut to 2;8,3.9 N.m (25-35 in-lb), minimum of 10 minutes is considered a used*' : 2,.

: Red on_e battery (BAT)terminal. Tighten nut belt, and when adjusted, It must_b:eadjusted to ":._,_ to3.4-6.2 N.m(30-55in-lb). the used belt tension sh;.own in the

' Orange on the field (FLD) terminal. Tighten specifications.. '_nut to 2.8-3.9 N°m (25-35 in-lb).

:19. Wipe thei_rearendbearing surfaceof the rotor' shaft with a clean, lint-free rag. BELT TENSION

.20. Positioni_,herear housing andstator assembly 1. Install the belt tension tool on the drive belt:: over the.,'rotor and align the scribe marks and check the tension.

='_ made di3_ingdisassembly.

:'24 Seat theimachined portion of the stator core 2. If adjustment is necessary, loosen the alter-' nator mounting bolts and move the alternator.... into the'stop in both end housings and install adjusting arm bolts. Move the alternator to-,' the housing throughbolts. Tighten the bolts to; 4.1-6.7 N-m (35-60 in-lb), ward or away from the engine until the correct_;,_ tension is obtained. Remove the gauge. _

_':_;_2.Remove::the wire holding,_th_'b_ushesi.... 3. Tighten the alternator adjusting arm bolt and,CAUTION: This step is Important so that reg- the mounting bolts. Install the tension gaugeulator will not be damaged: and check the belt tension. _-:

Z "i"

Page 481: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-01 Starter, Permanent Magnet 5a-01!

Part 5a.'Starter, Permanent Magnet

SUBJECT PAGE SUBJECT PAGE

;DESCRIPTION ANDOPERATION , DISASSEMBLYAND ASSEMBLY (Cont'd.)

Jump Starting .................................................,.-....... 5a-02 Cleaningandlnspecti0n.._.,. ..........:...........:..;..........5a-09 _, RoadService ............................................................. 5a-02 Starter DriveReplacement 5a-ll

• :Sequence of 0peration .........................., ............:...:5a-01 . ' REMOVALAND:INSTALLATION •

.DIAGNOSIS AND TESTING' " .Starter Motor ..........i ..............i .......................i .......... 5a-07

Bench Tests ............................................................. 5a-06 SPECIALSERVICETOOLS,.....' .........,..".'..,.::;_...i........ 5a-12

Systemlnspection ..........................................:......:.5a_03 ! SPECIFICATIONS.............................;............... ............ 5a-ll:' DISASSEMBLYANDASSEMBLY _' °

A_mature.Replacement 5a-ll

' DESCRIPTIONANDOPERATIONi

The function'of the startingsystemis to crankthe rTypical StarterShown,engine,at a speed fastenough to permit the engine to•start: Heavy cables,connectors,and.switchesare usedin the starting system becauseof the largecurrent

, required bythe starter while:it is cranking the-engine. ,The amount of resistancein the startingCircuitmust be

'. : ,:keptto an absolute minimum to provide maximum """ ': :_',i:,_,,-_,' " .i!.'_, ..:_._:,current for starter operation. A discharged or damaged \battery, loose or corroded connections, or partiallybroken cables will result in slower than normal z_=_"_,\ _cranking speeds, and may even prevent the starterfrom cranking the engine.

The starting system includes the permanent magnetgear,reduction starter motor with a solenoid-actuateddrive, the battery, a remote-control starter switch (partof the ignition switch), the starter relay, the heavycircuit wiring, and may include starter lockout devices.

Sequence of Operation 5. When the ironplungercore is all the way into the1. The ignition switch is turned to the START coil, its contact disc closes the circuit between

position, thebatteryandthemotorterminals.

2. A remote starter relay is energized, which 6. The current flows to the motor,and the driveprovides voltage to the starter solenoid. The piniongear cranks the flywheel and the enginestarter solenoidis energized, creating a magnetic crankshaft.field inthe solenoidcoil. 7. As currentflows to the motor, the solenoidpull-in

, 3. The ironplungercore is drawn intothe solenoid coil is bypassed.coil. 8. Thehold-incoilkeepsthedrivepiniongear

4. A lever connected to the driveassembly engages engaged with the flywheel.the drive piniongear to the flywheel ringgear.

Page 482: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

f

5a-02 -Starter, Permanent Magnet 5a-02 •• ", ." I

DESCRIPTION ANDOPERATION (Continued) -.. ........._,. r

9. The gear remainsengaged untilthe ignition WARNING: DO NOT DISCONNECT THE BATTERY, _:,switchis released from the START position.. OFTHE VEHICLE TO BESTARTED.I _ ..

_; DISCONNECTING THE BATTERY COULD DAMAGE ,.,.THE VEHICLE'S ELECTRONIC SYSTEM.

NegativeGroundedBattery -_SOLENOID PULL IN

,---_.----u---='_/_ _" COIL WARNING: TO AVOID ANY POSSIBILITY OF....... , !_.. INJURY, USE PARTICULAR CARE WHEN

I_' " CONNECTING A BOOSTER BATTERY TO A ., ,

STARTER',L_J _ HOLDIN DISCHARGED BATTERY ..... :.i_._, I _ I I COIL .....

,_-'_-*_.... II.j 1. Position vehicles so jumper cables will reach, ' "_-- beingcareful that vehicles do not touch.

BATTERY [4 " STARTER RELAY . ,

,_ ._l--IIJ:'.l _:::;_ 2. Make jumper cable connections.

"_ • Connect one end of first ju_10ercable to ..S- '='ll

;'_ START SWITCH _T NEUTRALSTART positive (+) terminal ofdiSCharged battery and' i_ _ _ _ SWITCHOR other end of positive (+) terminal of boosterii, ' _- J.'_/_---J LOCK-OUT SWITCH battery."i

:_ _:i' • Connect one end of second jumper cable to.'_ ,,;_,.... negative (-) terminal of booster battery.

An overrunnillg clutch in the drive assembly protects Connect other end to an engine bolthead or.....the starter fr6m excessive speeds during the brief good metallic contact spot on engine of

period before the driver releases the ignition switch equipment to be started, NOT TO NEGATIVEfrom the START position (as the engine starts). (-) BATTERY TERMINAL.

JUMP STARTING

I I MAKE CONNECTIONS IN NUMERICAL

Road Service ORDER (DISCONNECT IN REVERSE

; ORDER 4. 3, 2. 1) _

•_For cases 0f.a starter that cranks the engine very [___I "",:_.:..... slowly,connect a 12-volt booster,battery to the• .. •

system. '" ":' _ '__"_*'_" SECOND JUMPER G

- v I LI CABLE _ ¢: >"

__pE, 1" I==

,u=S,ar,i., i+,_o1 ,ooTo avoid damage to the vehicle and battery or the , ' MAKESUREVEHICLESpossibility of personal harm, follow these instructions DISCHARGED 00 NOTTOUCHandprecautions: BATTERY

WARNING: HYDROGEN AND OXYGEN GASES ARE WARNING: MAKING THE FINAL CABLEPRODUCED DURING NORMAL BATTERY CONNECTION COULD CAUSE ANOPERATION. THIS GAS MIXTURE CAN EXPLODE ELECTRICAL SPARK NEAR:THE BATTERY'IF FLAMES, SPARKS OR LIGHTED TOBACCO ARE AND COULD CAUSE AN EX_IbLOSION.REFERBROUGHTNEARTHE BATTERY.WHEN TO WARNINGAT THEBEGINNINGOFTHECHARGINGOR USINGA BATTERYINAN JUMP STARTINGPROCEDURE.ENCLOSEDSPACE,ALWAYSPROVIDE ........

CAUTION: When servicing starter or, VENTILATION AND SHIELD YOUR EYES. _' performing other underhood work in the .......WARNING: KEEPOUT OF REACH OF CHILDREN. vicinityof the starter, be aware that theBATTERIES CONTAIN SULFURIC ACID. AVOID heavy gauge battery input lead at the starter_CONTACT WITH SKIN, EYES OR CLOTHING. solenoid is "electrically hot" at all times.ALSO, SHIELD YOUR EYES WHEN WORKINGNEAR THE BATTERY TO PROTECT AGAINST Be sure to disconnect battery negative cable

, POSSIBLE SPLASHING OF THE ACID SOLUTION. before servicing starter.

IN CASE OF ACID CONTACT WITH SKIN, EYES OR • Make surejumper cables are notinway ofCLOTHING, FLUSH IMMEDIATELY WITH WATER movingengineparts.FORAMINIMUMOFFIFTEENMINUTES.IFACIDIS :_SWALLOWED, DRINK LARGE QUANTITIES OF • Start engine of vehicle withgoodbattery. Run.MILKORWATER, FOLLOWED BY MILK OF engineat a moderatespeed.MAGNESIA, A BEATEN EGG, OR VEGETABLE OIL. • Start engineof vehicle withdischarged"CALL A PHYSICIAN IMMEDIATELY. battery. Follow startinginstructionsinthe

: Owner Guide.

3. Completely dischargedbatteriesmay requireanelectrical load to initializecharging.

"_'_i

Page 483: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-03 Starter;PermanentMagnet 5a-03

DESCRIPTION AND OPERATION (Continued)

4. :-.Remove cablesin exactREVERSE sequence.• :;::Beginby, removing cablefrom engine ofvehicle ..: : ...:.....

that had discharged battery. --

If the starter does not turnthe engine over, even withthe booster battery, attached, refer to On-VehicleTesting.

_L

DIAGNOSISAND'TESTING

.:System Inspection . ..Besure to.disconnect battery,_negativecable before

•CAUTION: When disconnecting the plastic servicing starter•_=hardshell connector,at thesolenoid _'S" terminal. • 11..: :Inspect startingsystemfor, looseconnections:

grasp theplastic,connector and pul/!ead 0ff.DO 2: ' If system does not operate properly,note _:: " NOT pullseparately on lead wire: , condition and continue diagnosis using the

WARNING: WHEN SERVICING STARTER OR symptomchart.

PERFORMING OTHER WORK IN THE VICINITY OF WARNING:,WHEN WORKING IN AREA OF THETHE STARTER. BE AWARE THAT THE HEAVY ,STARTER, BECAREFUL;TO AVOID. •

,GAUGE BATTERY, INPUT LEAD AT THE STARTER TOUCHINGHOTEXHAUST COMPONENTS.•SOLENOID IS "ELECTRICALLY HOT" AT ALL .......... , ......TIMES.

, Symptom Chart

CONDITION . ' ' POSSIBLE SOURCE i, " " _ i, _,ACTION ....

Starter solenoid does not pull-in and • Open fuse. • _ Check fuse'continuity'i :" :4 _ _!',_"i_starter does not crank (Audible click • Low battery. • Refer to appropriate batterymay or may not be heard), service manual.

• Defective remote relay. • Go toTest B.• Open circuit or high resistance in • Go to Test A.

external feed circuit to startersolenoid.

• Defective starter. • Replace starter. See removal andinstallation procedure.

Unusual starter noise during starter • Starter not mounted flush • Realign starter on transmissionoverrun. (cocked). bellhousing.

• Noise from other components. • Investigate otherpowertrain, accessory noise contributors.

: . " • Ring geart0oth damage or '• • Refer to appropriate engineexcessive ring gear runout• manual.

• " Defectivestarter. • Replace starter. See removal andinstallation procedure.

Starter cranks but engine does not • Problem in fuel system• • Refer to appropriate fuel systemstart, manual•

• Problem in ignitionsystem. • Refer to appropriate ignitionsystem manual•

• Engine related problem• • Refer to appropriate enginemanual.

Starter cranks slowly. • Low battery.' • Refer to appropriate batterymanual•

• • High resistance or loose • Check that all connections areconnections in starter solenoid secure.battery feed or ground circuit•

• Ring gear runoutexcessive. • Refer to appropriate enginemanual•

• Defective starter. • Replace Starter. See removalandinstallation procedure•

Page 484: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-04 ' • ."Starter,Permanent.Magnet ' 5a-04

DIAGNOSIS ANDTESTING (Continued).. _._.,. --

• ,.CONDITION POSSIBLE SOURCE . . ACTION.

Starter'.remainsengaged and runs -:, _. • ,. Shorted ignitionswitch., :. ....... , _, , •.. Refer to appropriate ignition:':/_'with engine, system manual..

.... • Battery cable touching solenoid 'S' • Replace or relocate cable and' terminal (defective or replace starter.

.. mispositioned cable)• "• Defective starter. • Replace starter. See removal and _:_

".' installation procedure.

.. FPPO 1

-_,

Evaluatlot_Procedure 1

•; CAUTION,'i'Remove plastic safety cap on starter:_ solenoid and disconnect hardshell connector at

solenoid "S" terminal as described under"Removal and Installation" in this section.

..... CHECK STARTER MOTOR _ TEST A

• _•' TEST STEP RESULT • ACTION TO TAKE

A1 I CHECK FOR VOLTAGE TO STARTER• ';iKey OFF. Transmission inNeutral• Yes • GO to A2.

• "_'_Checkfor voltage between starter B+ terminal and No • CHECK wire connections, ,_starterdrive housing.

between battery and• i;Isvoltage OK? ( 12-12.45V) starter solenoid and the

,,:, ground circuit for open or" short.

A2 ICHECK STARTER MOTOR• ,,Key OFF. Transmission in Neutral. , , Yes • CHECK connections from• -Connect one end_of_a"ju_'per;wiret0:the starter B+ output of fender apron

terminal and momentarily touch the other end to relay to 'S' terminal forsolenoid 'S' terminal• open or short. ,_

• Does starter crank? No • - Defective starter. _"REPLACE starter.

FPPO2

Evaluation Procedure 2

CHECK RELAY _ TEST B

TEST STEP RESULT •i ACTION TO TAKE

B1 I CHECK FENDER APRON RELAY

• Key in START.Transmission in Neutral. Yes • GO to B2.

• Is case ground OK? No • REPAIR ground.GO to. ,,B2.

7_,.

Page 485: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-05 Starter,'Permanent Magnet "5a-05' I

DIAGNOSIS ANDTESTING (Continued) •

CHECK RELAY _,TEST B (Continued). ,

' ,, :, ,' :TESTSTEP- RESULT • ' ACTIONTOTAKE ........

.. B2 CHECK VOLTAGE ATREMOTE RELAY STARTTERMINAL

.... ' - • Key in START:Transmission Neutral. ' Yes • • GO to B3.

• . Check for voltage between relay start terminal and No • ,Open circuit orhigh, , ,case ground. _ resistance exists in

• Is voltage OK? (12-12.45V) external circuit wiring or• ,:components.Check the

• following: ....I ' : ' ." , " "' *t _-- ,'All,circuit,'connections'

! • ,:,,.including plastic'_, _ ha rd-shel I connectori

• ' _ ' " " _ .:'.:-:,,:l'.:at, solenoid"s".• . : ' ' _.terminal to make sure

" it is not broken ordistorted.

Ignition switch.Neutral switch or

manual lever position:sensor.

B3 CHECK OUTPUT TERMINAL VOLTAGE , ,• •

• •-' Keyin START:Transmission in Neutral. Yes :_, ,_., _,i::' :i:_ll_,REFERto;Starteri'System

• Check for voltage at output terminal of remote relay. , ....... . Diagnosis in this section.

., •. Is voltage OK? No ,1_ Defective remoterelay.REMOVE andREPLACE ::relay.

FPPO3

Starter Load Test 2. Place transmission or transaxle in NEUTRAL. :

Conduct this test if the starter cranks slowly and it is Crank engine with ignition off, and determinedesired to compare current to specifications, exact reading on voltmeter. This test is

accomplished by disconnecting push-on1. Connect Rotunda Starting and Charging Tester connector S at starter relay and by connecting a

078-00005 or equivalent. Make sure that current remote control starter switch from positive

is not flowing through ammeter and heavy-duty battery terminal to S terminal starter relay.carbon pile rheostat portion of circuit (rheostat atmaximum counterclockwise position).

Page 486: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

i

5a-06 ,Starter, Permanent Magnet. 5a-06.:' ",. . , . .1!1, " '-" "

.DIAGNOSISANDTESTING(Continued)- ,:,.'

3. •:.:Stopcranking-engine,-andreduce resistance of..::carbonpile untilvoltmeter.indicatessame reading ' ;"• . . ''

' _.,asthatobtained whilestarter.cranked the'engine::,:',:.- "._' The ammeter willindicate•starter current draw

under!'Dad.Check thiswith value listed in-; Specifications.• _:_

:"_ VOL'_UE'rER"...... " ":_

: " , I# TO OTHER CIRCUITS . SWITCH

' ll II -......... '•J I B =llm M I

-- SI"ARTER SWITCH r ..j_: ¢:_ _ I(0_.._"IGNITION SWITCH) _ :_t_ _ ¢_ T- I

I STARTERTO BAT]" STARTER j BATI'ERY SOLENOID

., %--

Bench Tests

Starter No-Load Test

The starter no-load test willuncoversuchconditionsas open or shorted windings, or rubbing armature. The rstarter can be tested, at no-load, on the test bench I _ _ I. VOLTAMPonly. " ".'," I ITmTrrlTI _ _ TESTER

POSITIVE _===0 "_ 0 l_;_:• 1. Make test connections with Rotunda Starting and LEADS /FI 'CI"_' ,1_'_:.,'N__ ':_f_'-,' NEGATIVE "

Charging Tester 078-00005 or equivalent cables _i•:connected to starter, large enough to carry high

. current (the same as in the vehicle). The starterwill run at no-load. Be sure that no current isflowing through ammeter (rheostat at maximum

: ,, counterclockwise position). Determine exactreading on voltmeter.

_.:_, CAUTION: Make sure that the starter is; securely mounted in bench vise while

, energizing, as starter will move or jump.

BATTERY

(CONVENIENT GROUND ON STARTERSUCH AS MOUNTING EAR ON CASTING.I

Page 487: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-07 Starter, Permanent Magnet .5a-07

DIAGNOSIS AND TESTING (Continued) REMOVAL AND INSTALLATION

2.' Disconnect starter from battery. Then, reduce Starter Motor,, resistance of.rheostat untilvoltmeter indicates .., Removal • , "

same reading as that obtained while starter was :running. :The ammeter will indicate starter.no-load WARNING::WHEN SERVICINGSTARTER ORcurrent draw.. Refer to Specifications for a PERFORMING ANY MAINTENANCE IN THE AREA

• , _comparativevalue. OF THESTARTER,NOTE THE HEAVY GAUGE,. INPUT LEAD •CONNECTED TO THE STARTER

3. If current exceeds,specification, check for I . SOLENOID is HOT AT_ALLTIMES, MAKE'SURE'," .,• 'rubbing armature, bent shaft, binding bearings, or THE PROTECTIVE CAP.IISINSTALLED OVER THE

.... ,'shorts.i narmature, ,or,brush assembly.-. TERMINAL'AND IS,REPLACED AFTER SERVICE.

•ArmatureOpen,Circuit Test 1.. Disconnect thenegativebattery ground cable..An open circuit armature may sometimes.be detected 2. ; Disconnect starter, cable:and push,on,connector

by.examining the commutator forevidence of burning, fromstarter solenoid: .A burn,spot onthe commutator s,caused.by an arc.

,formed every time thecommutatorsegment,, ..... . , . : , :_CAUTION:_When disconnectinghardshell"connected-to the open circuit,winding_ passes under a , ,. connector at S-terminal, grasp the plasticbrush, shell and pull off. Do not pull on wire. Be

careful to pull straight off to prevent damageGrounded ArmatureTest , to the connector, and S-terminal. If any partThis test will determine if the winding insulation has of the connection is damaged, replace the

, been damaged, permitting a conductor to touch the ..damagedcomponents.frame or armature core. To,determine if the armature 3. :_ Remove upper b01twitha,3J8 inch;drive ratchet,,windings are grounded,,check with a VOM as shown. .-., _swivel_socket/adda 22inch.long extension.

• Infinite resistance-indicates a normalcondition. Accessisin frontofandalong side'0f the. , right-handfront engine'mount.

4. Remove lower bolt.Installation

,1..Position starter motor,to engineand install upperand lower bolt finger-tight.

, 2. i]ghten the upper bolt tO21-27 N.m (i5-20 ft-lb).Access to upper bolt is with a 3/8 inch driveratchet, swivel socket and a 22 inch longextension. Access is in front of and along side ofthe right-hand front engine mount.

3. "lighten the lower bolt to 21-27 N.m (15-20 ft-lb).4. Connect starter solenoid connector. Be careful to

Starter Solenoid Test push straight on and make sure connector locksin position with a notable click or detent.

Make sure that the solenoid is isolated electricallyfrom the motor. Using a VOM, check.for continuity , • 5. Install starter cable nut to starter terminal.

"l]ghten to 9-13 N.m (80-120 imlb).between S terminal and M terminal, and between S ,terminal and ground (frame). If there isno continuity, .- ' 6. - Replace red solenoid safetycap.the wire is broken and the'solenoid should be 7. Connect negative battery ground cable.replaced,

Wiring

It is recommended that wiringservice kitF2PZ-11K 162-A be used, which includesa 70 inchlong # 12 gauge wire, a terminal nut, a terminal cover,four tie wraps and insulationinstructions.

I

Page 488: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-08 ' Starter, PermanentMagnet 5a-087 :/" " "

REMOVALAND INSTALLATIONIContinued) °::' :,,. _.

BATTERY.

CABLE #12GAUGE.. , WIRE (RED)

E9SF-11A004-AB

STARTER ST;_RTER"CABLE RFLAY

TERMINAL

CAUTION_,:_Ajumper wire must not be Installed_ betweenthee large round electrical terminal and, : the solenoid blade terminal at the starter, to:avoid usei_f the # 12 wire. If done, voltage Is .....

generated_to the solenoid by the spinning starter: after release of the start key or button, causing

the starter_:to remain engaged, resulting in failure.

._ , STARTER

:_ . _:i:_ _ ' MOTOR

: ' ._ _ SOLENOID SOLENOID

• _" • • BLADETERMINAL

FIELD \WOUNDSTARTER _:'_":\ "

! PERMANENT .MAGNET TERMINAL ,_;

STARTER COVER

"f

Page 489: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-09 " Starter, Permanent Magnet • 5a-09

DISASSEMBLY AND ASSEMBLY

Starter Motor, Exploded ,View

TERMINAL NUT STARTERN80.5403 SOLENOID DRIVE . _

END

11390 HOUSING

, 11130

HOUSING SEAL ..............._ _,____

• ASSEMBLY _ pi_11A171

'STARTER MOTORBUSHING . "SOLENOID SCREW

'BEARING _ _ N805405 . _,ASSEMBLY11135 _" '11000

ARMATURE _ "

ASSEMBLY11oo ARMATURE" ' DR,rE.. THRUSTB , LEVER' "_ 11A172 ' PLANET _ 11070

, GEAR __ iir -_"__t,(j_-._-/_.,_ ] _ 11K?0 STATIONA_Y_.

"-"'_V'_7 _P(_._))_ _ ASSEMBLY _. _F(J' " DRIVE__ _ }_ V_"_ _ 11A165 _ 'TRU_G,_,-..,._ ..... ASSEMBLY

T.RUBOLT L-- ___ '.J _ _:'

" _ __ _' ".-_ ARMATURE. THRUST. _,__ ,. J'

H ' " "" ' " STOP RINGB_ ..MAGNET_\ i _ R_TAINER, SCREW J_J'*____ ._" 6 REQ:D" /'11A168 "_• N805406

; ___' __-_------_' 6"REQ'Dt,".STOP RING :BRUSH END

PLATE SPRING '" "

BUSHING 11059BEARING 4 REQ'D BRUSH RETAINER

1113.5 ASSEMBLY FRAME _ 11A16911434 11076 6 REQ'D

Disassembly Cleaning and Inspection

1. Remove positivebrushconnector from solenoid CAUTION: DO NOT WASH THE DRIVE BECAUSEmotor (M) terminal. ...... .... _ _ ' THE SOLVENT WILL WASH OUT THE LUBRICANT

2. Remove solenoid retain!ngscrews,andsolenoid. CAUSING DRIVE TO SLIP. USE A BRUSH OR. COMPRESSED AIR TO CLEAN THE DRIVE,3. Remove through-bolts and separate drive end ARMATURE, BRUSH, AND GEAR ASSEMBLIES,

housing from motor frame. Remove housing seal DRIVE END HOUSING, POLE PIECES AND PLANETassembly from drive. Remove drive and gear GEARS. WASH ALL OTHER PARTS IN SOLVENTassembly from drive end housing. AND DRY.

4. Remove drive lever from drive assembly. Remove 1. Inspect armature windingsfor broken or burnedstop ringand retainer from driveshaft, then insulationand unweldedoropen connections.remove drive assembly from shaft. PushC-ringoff driveshaft, and separate gear assembly from 2. Check armature for open circuits, shorts anddriveshaft, grounds.Check for pole rub or rub onmagneticshunts.

• 5. Remove brush plate screws and brush end platefrom motor frame. Remove brush assembly andpush armature out of frame.

Page 490: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

r

5a-10 - •Starter_ Permanent Magnet 5a-10• . : _ I IIII I I

, _,_.DISASSEMBLY AND ASSEMBLY(Continued) ,._.._,-_:.... . .

•3. •,Check commutator for runout.Inspect armature.. : • _;'!_- COMMUTATOR RUNOUT CHECK_ '." . ....;shaft and two bearings for scoring and excessive._._ " . _

., ":'_wearwith Dial Indicator-TOOL_4201-C or :" ...,_ . -" DIALINDICATOR ' '" "

;: equivalent. If commutator, is rough, or more than TOOL4201-C0.12mr_ (.005 inch) out of round, it must be R =}_-_ Rreplaced.

,:=.,_,, f

"-'V"" BLOCKS J2711-tB

4. Examine gears, spiine ondriveshaft, anddrivepinionfor chipped, broken or wornconditions.

. ' " Replaceif required.: t

"_ PINION AND RING GEAR WEAR PAn'ERNS

-':_"

. : _...'. %_ (_

MILLED CONDITION EXCESSIVE

WEAR ON 2 OR 3 TEETH ' _-;

(__ ( MILLED TOOTH-METAL BUILD-UPIT ENGAGEMENT

SMALL WEAR PATrERN

NORMAL VVEAR PAl-tERN _ MILLED GEARS

..r_,

4, Apply grease into drive end housing bearingbore.Assembly . ,,_:!._- Install armature assembly instarter frame. Apply (approximately one-quarterfull). Installdrive gear. .....:

a thin coating of ESF-M 1C218-A Grease or assembly into housing,making sure to lineup bolt ,_equivalent low temperature grease on both ends holes in gear assembly and housing. Place gear

:_:i, of armature shaft and spline. Install brush retainer over gear assembly. Install housing seal....?_;" assembly ensuring brushes fit over commutator, assembly into drive end housing.

, ._.:_ Apply grease to bearing bore in brush end plate. 5. Position starter frame to housing and install:- " Push back grommet onto frame and attach brush through-bolts. "13ghtento 5.0-9.5 N.m (45-84, end with brush plate screws. ]]ghten to 2.3-3.4 in-lb),

= N.m (20-30 in-lb). 6. Correctly position solenoid to housing ensuring ,;;::_21 Apply grease to driveshaft spline and place that solenoid plunger is attached through drive"_.'_' stationary gear assembly over driveshaft. Install lever (bottom solenoid terminal (M) should have a

,;:: armature thrust washer and push C-ring onto metal strip attached to it). Tighten solenoid bolts..,_ _-

...._',,_ driveshaft. Place drive assembly onto shaft and to 5.1-9.6 N.m (45-85 in-tb).

install stop ring and retainer. Attach drive lever to 7. Attach positive brush connector to solenoid• drive assembly. (bottom terminal). Tighten nut to 9-13 N.m

3. Grease and install planet gears. (80-120 in-lb).

Page 491: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-ll Starter,'Permanent Magnet 5a-llI

DISASSEMBLY AND ASSEMBLY (Continued)"

. 8. - Check that starter no-loadcurrentdraw is within.• :._:_specification.,Refer to BenchTests.. " ..

..... Starter Drive Replacement .. ,, :-.5. Partiallyfill drive end flousing bearing bore with

1. Remove positivebrush connector fromsolenoid .........grease(approximatelyone-quarter, full). Install

:'motor(M) terminal:Remove solenoidretaining " •. drive gearassembly in housing,making sure to' .

• :screws and remove solenoid. -., line up bolt:holes ingear,assembly and housing.

. 2. ,Remove through-boltsandseparate motor ' : 6. ,Install lever,:supportand housingseal indrive endassembly drive endhousing:Remove housing housing.

,. : ,"-..seal from drive end housing.Remove drivegear 7. :-.Position:starter:frame_tohousingand'install.... assembly from housinganddetach drive lever,..... .... through_bots:,,'_ghten_to50-9 5N.m (45-84

•. 3.." .Remove stop ring and retainer from driveshaft . in-lb). " _," ,and then remove drive assembly. ,_,' - _ ,, .... 8. Install solenoid. Refer toAssembly. •"

.4.,. Apply a thin coating of ESF-M 1C218-A Grease or•equivalent low temperature grease on driveshaftspline. Install new drive gear assembly ondriveshaft..Install newstop ring and retainer.Attach drive lever.

Arrriature Replacement ...... . 5.,'._:lnstallbrush:assembly. Using tool.make Sure that

•1. Remove positive brush connector from solenoid .... ,, brushes fit over,commutator., Pushblack• motor (M) terminal. ';, : :grommet ontoframe:,Applygreaseto bearing

, " :.... borein brushendp!ateand attach to starter2.: _"Remove throUgh-boltsand separate motor from• • " frame. " '

....gear assembly and drive end housing, i. 6. Position starter.framelto gear:assernbly_and drive ''.,_',. _ '....3. ' Remove brush end plate screws, brush end plate ... , end housing and install,through-bolts. "13ghtento

and brush assembly from starter frame. Remove• 5.0-9.5 N.m (45-84 in-lb).

armature from frame. 7. Attach Positive brush connector to solenoid4. Install new armature in frame. Apply a thin coating (bottom terminal). "13ghtennut to 9-13 N.m

of ESF-M 1C218-A Grease or equivalent low (80-120 in-lb).temperature grease on both ends of armatureshaft and pinion. 8. Check that starter no-load current draw is withinspecification. Refer to Bench Testing.

SPECIFICATIONS

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (Cont'd)

Description N.m Lb-ln Description N.m Lb-ln

Solenoid Bolt 5,1-9.6 45-85 B Terminal Nut 9.0-13.5 80-120

M Terminal Nut 9.0-13.5 80-120 Through-Bolt 5.O-9.5 45-84

(Continued) Mounting Bolt 20.3-27 15-20 (Lb-Ft)Brush Plate Screw 2.3-3.4 20-30

StarterMotor StarterBrushes

Current Draw Normal EngineMoto¢ UnderNormal Cranking MIn.Stall"

D_ameter Load Speed Torque@ 5Volt= Max.Load No Load Mfg.Length SpringTension

mm I Inches Amp= RPM N-m Lb-R Am_ Amp= mm Inchel N I oz.78 J 3 140-200 2_0.250 14.7 11.0 800 70=10 16.8 0.66 18 I 64

_tor nJnoutis0.12turn(0.005inch)Maxin_mstarlingcircuitvoltagedrop(batterypositiveterminaltostartertorminaJ,atnormalengineten_oer_reis0.5volt

Page 492: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5a-12 " ."Starter:.Permanent Magnet -_....... 5a-12" I I : "

SPECIAL SERVICE TOOLS ...._' _

I': -_' ROTUNOAEOUlPMENr . _!_:" 078-00005: " ' Starting'and ChargingTesi_r ..... ' "

" ''_L / I

TOOL.I"O ASSEMBLE BRUSH HOLDERTO ARMATURE . I

PRESS FIT ,i:. .. I I- ' -I il ';,_.:_

•_ 6"2 '

BRUSHHO'OERASSEMBLY(_ MANOREL

,_. _'_ MAT'L: MICAATA LL221TAN-TYPE FBL "_:

'" (1)'_REQ'D_!_;:_; .'... (_) BUSHING' _ UNIVERSAL HEADLESS TYPE

PRESS FIT BUSHING :_i,_CA]'. NO, GS-93.471/.472 I.D..7518 O.D..750 LG.(1) REQ'D

,,,

,c.

Page 493: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

"5..01 STARTING SYSTEM 5-01IIII •

Part 5--- Starting System

........................'SUBJECT PAGE SUBJECT ' PAGE

•' ' .::DESCRIPTIONANDOPERATION...." ' .. 5-01 TESTING(Cont'd.) ,TESTING StarterNo-Load-TesL:... i.....'.. . i.. i r:.... . i' 5-04 "_

RoadService ............................... 5-02 .ArmatureOpenCircuitTest ................. 5-04_Jump.Starting.................................... 5-02 • ArmatureandFieldGroundedOnVehicleTesting ........................... 5-02 .... CircuitTest "5-04IfStarterCranksSlowly ......................... 5-02 REMOVALAND1NSTALLATION...:._i.:........... 5-05If StarterDoesNotCrankBut .. DISASSEMBLY;AND,;ASSEMBLY • '

• .StarterRelay_Opefates,(Clicks).' .5-03 Disassembly, .............................. .5-05.IfStarterDoesNotCrankand CleaningandInspection...................... 5-05

RelayChattersor DoesNotClick............. 5-03 Assembly................................... 5-08

If StarterSpins(HummingNoise) .'StarterDriveReplacement..................... 5-08.,_ButDoesNotCrankEngine..... .......... .: :. 5-03 : Brush'!Replacement_:_.._.,:.,.. :.,.:';i._:::,......... 5-09

StarterLoadTest .................... ,.......... .5-03 ". ' Armature,Replacement: _..: . ,....... ..... 5-09BenchTests ................................. 5-04

" DESCRIPTION AND.OPERATION

- , ,:>Thestartingsystem includes_the;starter:motor: _.-thebattery, current',flows".through,the grounded,-withan,,integral positive,engagement .drive, the - . : field coil.,actuating,a'rdo_ablep61eshoe_Th_p61_= _''_

i;:i ....

, battery. a remote control starter switch (part of the ' shoe is attached to the starter drive plunger leverignition switch), the neutral-start switch (used with and thus the drive is forced into engagement withautomatic transmissions), the starter relay, starter the flywheel ring gear.interlock switch (used with manuat transmission),and heavy circuit wiring. When the movable pole shoe is fully seated, it

opens the field coil grounding contacts and theTurning the ignition key to the Start position starter is then in normal operation. Normal field

actuates the starter relay through the starter con- currentis used to maintainthe movablepole shoetrol circuit. The starter relay then connects the in the fully seated position during the time that thebattery to the starter, starter is cranking the engine.

Vehicles equipped with,anautomatic transmis-

sion have a neutral,start switch,in the starter con- • L_B_!-T-£_,; s,,,,,, ,,LA___'troI circuit. This prevents operation of the starter -

on vehicles with an automatic transmission if the s_,.__ FI _" _selector lever is not in the N (NEUTRAL) or P "STA_TS_,.TC..NO_FPOSmO_

(PARK) position. _ _ / • l _ JWhen the starter is not in use, one of the field STA,TER

NEUTRAL START SWITCH

coilsis connected directly to ground through a set (AUTOMAT,CTRANSM,SS,ONO_t.YJof contacts. When the starter is first connected to o,CLUTCH INTERLOCK'SWITCH

(MANUAL TRANSMISSION ONLY) J1083-1N

Page 494: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, 5-02 -STARTING:SYSTEM : 5-02'I " ,

TESTING :

ROADSERVICE _ ' I. Turn _l":lamps off before and,during jump .....starting......

On road 'service calls.or cases of a starter that , ..... 2. Turn on heater blower motor to remove tran-' ;i: will not crank the engine or a starter that cranks sient voltage.-_:4 very slow!y_ a booster battery may be connected..::-to the 12-volt system. If the engine still will not turn 3. Shield eyes. Use safety goggles or similar eye ._,

: ..',,:,with the b0:oster.connected, refer to the following protection. "

'-- tests: _ 4. Connect ends of one cable to positive (+):" :_ terminal of discharged battery and the other _i

_._i_TO JUMi_'_START (NEGATIVE GROUNDED end to the positive ( + ) terminal of the booster ':

_ BATTERY_! battery." _.,_:, 5. Connect one end of the other cable to nega-

:'ir WARNIN_:iBATrERIES ARE HEAVY, WEIGH- tive (-) terminal of"good" batte;_.::_:_ ING 30 LBS. OR MORE. LIFT THEM WITH ,._

YOUR LEGS RATHERTHAN YOUR BACKTO 6. Connect other end of cable to engin'ebolthead•' PREVENT MUSCLE STRAINS, AND BE CARE- or similar good contact spot on"the vehicle

::: FUL NOTTO DROP THEM (POSSIBLE BREAK- being started (NOT to negative (-) terminalLi,,' AGE) NOR TO SPILL THE CONTENTS of battery).':_ (SULFURIC ACID). 7. Make sure jumper cables are not in the way of

._ :_; moving engine parts.,.: CAUTION_ 12-volt starting motors can be 8. Start engine of vehicle with the booster bat-

. :, damaged:!beyond repair If connected to a 24- tery and run at moderate speed.:, volt power supply (two 12-volt batteries in se-

ries, or a,_24-volt motor-generator set), even 9. Start engine of vehicle with discharged bat-. when cra0king loads are relatively light. Ex- tery. Follow starting procedure described in

_:: tenslve sta'rting motor damage is more likely If owner's manual. .,_-!.the starte'_ Is connected to a 24-volt supply 10. To prevent damage to other electrical compo- :.:"

./..._ while belng_subjected t0. pr.oL0nged_._heavy nents on vehicle being started, make certain.: cranklng loads such as attempting to start an that engine is at idle speed before disconnect-

engine in subzero temperatures, ing jumper cables.

11. Remove cable from engine block before dis-CAUTION: To prevent damage to electrical or connecting cable from battery positive termi-lighting components during jump starting, the nal. Lamps may now be turned on.following procedure must be followed:

ON VEHICLE TESTING _.

IF STARTER CRANKS SLOWLY MA_ECONNECTIONSINNUMERICALORDER (DISCONNECT IN REVERSE

1. BATTERY -- Use jumper cables per instruc- ORDER,. 3,2,,tions. If this corrects problem, check condition ":. _..._,-'/-'_lg . .

., of battery, recharge or replace if necessary.Clean battery posts, cable lugs and tighten.

2. CABLES -- If the above'does not correct the SECONDJUMPERCASLE,[,O--'--']..='

:"_ problem, clean and tighten connections at Q__ I I_ _'

'.: starter, relay and battery ground on engine. [? o_I

O 0 =m+1. Eyelet terminals should not be easily rotated

_: by hand. Also check for short to ground. O,SC.ARGEO MAKESUREVEHICLES•

3. STARTER-- Ifthe above does not correct the BATTERY DONOTTOUCHproblem, replace starter. GASOLINEENGINE J2571-1B

Page 495: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5-03 STARTING SYSTEM ' 5-03

•TESTING (Continued)

IF STARTER DOES NOT CRANK BUT IF STARTER SPINS(HUMMING NOISE) BUT,::STARTER RELAY-OPERATES(CLICKS) • • . DOES NOT CRANK,ENGINE ..=

i. BATTERY .m •Use jumper cables, check bat- . STARTER .... Remove- and :check armaturetery, etc:.as above, shaft for corrosion, clean or,replace. If no,corro-

sion, repair starter:or replace.the starter• drive..',. 2: CABLE,_ Clean and tighten•connections at

•starter and relay. Make sure wire strands are STARTER LOADTEST _' •• '

secure in. eyelets. Conduct this tesLif, the starter cranks slowly and,3. :• STARTER--.If the above does not correct the. • acompa_ison of the.current output.with specifica-

problem,, replace starter, tionsis desired. " ' • : "

-IF. STARTER• DOES 'NOT, CRANK AND :. Gonnecbthetest-equipment_as:sh0wn; Be sure'" REL;AY..CHAT'rERSOR; DOES'NOT!CLICK .... . •• that no current is flowing thr0ugh thei'ammeter and

...... heavy,duty carbon_pilerheostat .poilion of the cir-1. /BATTERY --, Use .jumper cables;, check bat- • -"tery, etc: as ,_b0ve, : .. - cult (rheostat at maximum counterclockwise

position).

2. RELAY -- Remove push-on connector from Crank the engine with the ignition off, and deter-relay (red w/blue stripe wire) and make sure '. mine the exact,readingonthe voltmeter. This testconnection'is cleanand,secure. Make sure _ is-accomplished;by_idisc0nnecting_the push,onrelay bracket is grounded. . connector."S":'at the,starter relayandbyconnect-• .Ifconnections are good; check operation by .....:.ing .the_.;:r,em.ote..:contro "starter •switch 'fromthe

. .jumping .with •push-on .connection off. and .- _ : positive batterY terminal:to the.'_S":.termna of the,, transmission in.PARK or.NEUTRAL Jumper starter, relay.

above described terminal-to•relay main termi-/- .Stop cranking,theeng ne :Thenreduce:,the re-nal (BAT side) or battery positive post: If this ......" •sistance.of_the carbon_pile"until the voltmeter indi-• ' corrects problem,checkignition switch ned- ' " r:..... " ' . cates the,same, reading'as that obtained while the

. • ,.tra! switch and wiring in start circuit for openo[ ' .. startercrankedtheengirie::The ammete_ will indi-• loose connections. ' .... '" . cate thestarter currentdrawunder ioad.::(Refef:_t0_:;_,,_',_::

if jumper across relay does not correct Specifications at the end of this section.)problem, replace relay.

VOLTME TE_f,,tl' _ /CARBON PILE RHEOSTAT

j_=_,)_ _ AMMETER "" POSITIVE

f ' TOO'HERC,RCO,TS J --

- ton ,Ga,r,o_ I" I _ l_I I¢:T:_

__1 _"SWITCH_I ill /L_ _TO 8ATTE RY

NEUTF; AL 5T_'ART SWITCH STARTER(AUTOMATIC TRANSMISSION)CLUTCH INTERLOCK SWITCH "

(MANUAL TRANSMISSION) J10816-2M

Page 496: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

•:5-04, , :"_STARTINGSYSTEM" 5.04: ....

TESTING (Continued) " _..

BENCH TESTS

STARTER i NO-LOADTEST.......• ,.,,. The sta_er no-load test will uncover open or Grounded field windings can be detected by• _: shorted windings, rubbing armature, and bent ar- making the connections as shown. If the voltmeter ,_,i

• ., mature sEaft., indicates any voltage, the field windings are •:" ""The starter can be tested, at no:load_;onthe test grounded.

.;', bench or_iy:. :'?' , ,_:,•._=',__ ! "v _£

•:_ Make the test connections as shown.The start- •_-er will run_at no-load. Be sure that no current is

_ii flowing t_ugh the ammeter (rheostat at max- " . •imum co{_nierclockwiseposition). Determine the (.i -DO.NOTCONNECT

• '_EAO TO BEARING

;,,;. exact reading on the voltmeter. _,;_SURFACE

,-;' .os,T-!vE

• ' __' :t' (il_ ;i _'_ii_!.iiiiiii=;iii:_ii!I::::NEGATIVE LEAD i. !

VOLTMETER POSITIVE LEAD ' :_!; "::i"::i_:;_i!_',!:;i ...... !'' A"FIME,_, ,_ '* TOUCH TO COMMUTATOR J1088-1F

=

@KEEP BOTH FIELD BRUSHESBA'FrERY STARTER J10B7.1G --AND HOLDING COIL GROUND

LEAD AWAY FROM FRAME

Q CO .N.NECT VOLTMETERJUMPER LEAD_/'7_ POSITIVE LEAD TO

TERMINAL EYELET

• ARMATURE OPEN CIRCUIT TEST /

.. ,. s_An open circuit armature may sometimes be

:?detectedby examining the commutator for evi- .,.,.t _ TO::i,dence of burning. A spot burned on the com- VOLTMETER._mutatoriscausedbyanarcformedeverytimethe:;,commutatorsegment, connected to the open cir-!_'!:cuitwinding, passes under a brush. T_ LEAD

_:,tARMATUREAND FIELD GROUNDED:_;;CIRCUITTEST \

(_)DISCONNECT HOLDING COIL QINSERT INSULATOR ...._:" t,,..GROUND LEAD (FINE WIRE BETWEEN CONTACTS "=i

• _ This test will determine if the winding insulation INSIDEFRAME} " J3566-1A. '_has been damaged, permitting a conductor to

:_.touchthe frame or armature core.

,!J_iTo determine if the armature windings are• ;!_!grounded, make the connections as shown. If the_;i_oltmeter indicates any voltage, the windings are•_gtounded.• :Z.

Page 497: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5-05 STARTINGSYSTEM 505m

REMOVAL• AND INSTALLATION

REMOVAL 3. Remove the stop ring retainer. Remove anddiscardthe stop ring retaining the starter drive _

1. Disconnect the negative battery cable. " gear to the end of the armature shaft, and

2.. Raise.the. vehicle• on a hoist. " remove ,the starter-drivel gear assembly.. 4. Remove.the brush. end plate and .insulator3. 'Disconnect thestarter cable at the starter " • .

terminal, assembly.5.. Remove brushes from plastic brush holder

4..Remove.the. starter mounting bolts.,Remove .and •lift-.out brush,holder..:Note Iocationofthe. starter assembly. ' • brushbolder withrespect,to;end'.terminal.

.-.6:, :'Remove,the two:screws .retaining the ground. brushes_i0.frameJ_(The4:-inch:s!a_er has cop- '

. .per<rivetsl.),. .,.... .....

7_. On the field coil, that operates the starter drivegear actuating lever, bend the edges on thefield coil retaining sleeve and remove thesleeve and retainer.

:8...!Remove,the;.threeicOil,retaining!Screws using• ....anarbor.press::The arborpressprevents the........wrench.from:slipping outof the.screw. Cut the.ffield _coil:;connection_at the _switch, post lead.,:and,,removethe:small diametei" ground.wire

......... ' '._ .'.. from:theupper4ab.rivetedto frame: RemoveJt085-1D

, .pole: shoes and. coils. •from. frame.

POLE SCREW USE _-\RBOR PRESS" TOOL-I0044.A ,.. .... .T,O,_.{OLDTOOL .

"_-- "," SCF,EW SOCKET

,NS A,,A ,ONhousing, and start the mounting bolts.

2. Snug all bolts while holding the starter square-ly against its mounting surface and fully insert-ed into the pilot hole. Tighten the bolts to 21-27 STARTER_llr(:;t_lll EIlUiIFR,_MEN'm(15-20ft-lb).

"v" BLOCK

3. Connect the starter cable. BESURErOSEArOR,VE_,L_i;/A_ll__l4. Lower the vehicle.;COnnect!negative battery " ' .EAO,,SCRE',',SOCKET_'_'"Jl' I ,,0S_,F

• " cable to battery...Check:.the operation_,of the :.,.starter. 9. Cut the positive brush leads from the field

coils, as close to the field connection point aspossible.

DISASSEMBLY AND ASSEMBLY

Use the following procedure when it becomesnecessary to completely overhaul the-starter..The CLEANING AND.. INSPECTIONfigure on page 5-06 illustrates a disassembledstarter. 1. Use a brush or air to clean the field coils,

armature, commutator, armature shaft, brushDISASSEMBLY end plate, and drive end housing. Wash all

other parts in solvent and dry the parts.

1. Remove the cover screw, cover, and through 2. Inspect the armature windings for broken orbolts, burned insulation and unsoldered or open

2. Remove the pivot pin retaining the starter connections.

gear plunger lever and remove the lever, the 3. Check the armature for open circuits andstarter drive end housing, and lever return grounds.spring.

Page 498: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

5-06 "STARTING;SYSTEM, :" 5-06,'" ii . ....'. '

DISASSEMBLY AND ASSEMBLY (Continued)_ ,,

COVER ASSEMBLY

11060 COVER SCREW ' . " _'\"-_ ,_ _. '_t_r-

389614 d

._.._ ASSEMBLY

:_SPRING " " " " 389393 _/' _j_

1 i.

.,_' KIT • STARTING -, ':_. _" CONTACT

_'f POINT-11134"SCREW POLE

PIECE-11415

:3116 GROMMET "_

..2.

FIELD COILS

HOLDER - BRUSH11061

INSULATOR -HOLDER

11062BRUSH

_ 11056 ,11052389394

PIN

1182 BRUSH 1091.... "" I .I055 _ ,"_

qG _/_ _k _;;r_: _._.>_: SPR,_-BRUSH11222 11059

_ .\k // "_U"_ /_ MOTOR DRIVE _ BRUSH END

/ "l ,,"_ FLANGE..__.._,1o5o 111o,HOUSING111_5'--_( _(_._ ,1106_'_"%_

ASSEMBLY - "0"-- _ __ - _ "_

,,.o _/S_ _ I_lll(fll/Ik/<_s_z_ \_SLEEyEI

CORE ASSEMBLY J_l,_J_ "_ l

11005 / _ _-,JB

/POLE PIECE

i,.,;.t 1120 J3567-2A:,

• .......

Page 499: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:5-07 -STARTINGSYSTEM " 5-07I

DISASSEMBLY-ANDASSEMBLY (Continued)

4. ,Checkthe commutatorfor runoutusing Dial 5. Check the plasticbrushholderfor cracksor_, ,IndicatorTOOL-4201-C.,Inspectthearmature .... brokenmountingpads.Replacethebrushesif

shaft_and the. two bearings for ,scoring and ,' • ,.worn.to6:'35mm,(1/4inch)in le.ngth,Check the- ' excessive,wear.lfthe commutator is rough, or ..... .• , .._field brush connecti0ns;A brush kit and con-

. ,more' than ,0.127mm,_(0:005 inch).•out-of- ,. ," ,. '.....tact kit'ai'e,available.,AIIother assemblies are•, ,round, turn it down., ' ' , .to.be.replaced.rather,than,repaired. .

6.. ,.Examine the wear pattern on the starter drive"DIAL•INDICATOR :teeth:...:The_pinion_teeth :must penetrate,to aTOOL-4201-C

\_ S _ depth g_ea_e_,_han;one_alf the_ing_ gear tooth _

. ..depth;;,i:to;,_eliminatepremat'ure_ringgearand.... ,"_"starter;drive_f_i!lJre:..:;'", i. _ i!'_,;i:

ROTATE' ARMATURE" SHIAFTS ON y."' j ,. 7.,._RePac"e,sta_de'rildriyesi:a'n:dringgearshaving.BEARINGSURFACES _ _ milled, pitted or .broken:teeth"or:,that .show

•• evidence of inadequate engagement.

" "V'"BLOCKS

• J2716-1A

' . '- ,_ . ,

_ __0 MILLED CONOITION. EXCESSIVE

WEAR ON 2 OR 3 TEETH

NORMAL WEAR PATTERN, SMALL WEAR PATTERN

MILLEO GEARS

J1372-2C

Page 500: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

"5-08/ :" STARTING';SYSTEM 5-08:

.,,DISASSEMBLY.AND ASSEMBLY (Continued)_ :.....

-ASSEMBLY

/:,' :"1.'.' Posi!ion the three-coilsand pole pieces,then _ " = _ r '_:'_'i:'_" ' instai!_theattaching screws. As the pole shoe '-'• " ' screws are tightened,strike the frame several STARTS,O",VE _i_'

sharpblOWSlnstailwith a soft-faced hammer to seat Ac'ruAT,N_co° _ _ .

_and._alignthe pole':shoes, then':stake the ANO.OLD,Nscrews•

"2. the remaining coil and retainer and i!i_!, ber_d_;t'hetabs to secure the coils to the frame. 0

s

3. Pos'_ionthe new insulated field brushes lead : . _,on t_e:field coil terminal. Install the clip pro- " .i_ '

':- :' " vide._"withthe brushes to hold the brush lead -:;._:.._i_::,. to the terminal. Solder the lead, clip, and ter- i

minal together,•usingrosin core solder. Usea

.i_,;:il. 300 watt iron.

'_ 4. CheCksembled,_fOrcoils.COntinuityand grounds in the as- _,i_°2!i_•_i.: 5. The_coilwhich is around the retaining sleeve

is to!_begrounded by positioning the small "diameter wire leading from it, under the cop-i_er,.i:abheld by the rivet which attaches thecontact to the frame.

.-_-,.,.6. Attac_h.thegroundbrushes to the starter framewith._the,screws. (4.0-inch starter has copper 10. Position the starter drive plunger lever return ,i_:_._,rivets:)., spring and thedrive end housing to the frame.

• Install brush holder, insert brushes and."i. 7. Apply a thin coatingof Lubriplate777or equiv- springs. Install brush holder insulator.:-. alent on the armature shaft splines. Install the ,_:!i_

starter motor drive gear assembly to the ar- 11. Position end plate to frame, align plate locater ,_'."mature shaft and install a new retaining stop with frame slot. Install and tighten the throughring. Install a new stop retainer, bolts to 6.21-8.47 N°m (55-75 in-lb). Do not

pinch brush leads when installing end plate.8. Install the armature in the starter frame. Install pivot pin.

9. Partially fill the drive end housing bearing bore 12. Position the drive gear plunger lever cover onwith Grease ESB-M1C.63-A or equivalent the starter and fasten with the cover screw in(approximately 1/4 full). Position the starter the frame. "drive gear plungerlever to the frame andstart- , -er drive assembly. 13. Check the starter no-load current'draw.

,_,:,.STARTERDRIVE REPLACEMENT

' 1. Removethe starterdrive plungercover. '6. Positionthe startergear plungerlever on thestarterframe. Besure that the plunger lever2. Remove the pivot pin retaining the starterproperly engages the starter drive

driveplungerlever, assembly.

3. Loosenthe throughboltsenoughto allowre- 7. Installa newstop-ringretainer.Partiallyfillthemoval of the drive end housing and the starter drive end housing bearing bore with Greasedrive plunger lever return spring and lever. ESB-M1C.63-A or equivalent (approximately • • .....

4. Remove the drive gear stop ring retainer and 1/4full). Position the starter drive plunger lev-stop ring from the end of the armature shaft er return spring and drive end housing to theand remove the drive gear assembly, starter frame, and then tighten the through

bolts to 6.21-8.47 N.m (55-75 in-lb). Install -5. Apply a thin coating of Lubriplate 777, orequivalent on the armature shaft splines. In- pivot pin.stall the drive gear assembly on the armature 8. Position the starter drive plunger lever covershaft and install a new stop ring. on the starter. Tighten the attaching screw.

Page 501: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

"5-4)9 STARTING SYSTEM 5-09III

DISASSEMBLY AND ASSEMBLY (Continued)

"" :I BRUSH 'REPLACEMENT ARMATURE REPLACEMENT.

, . Replacethestarter brushes whenthey areworn . , 1. Remove.starter drive plunger lever cover re-_ 6:35mm(1/4inch)."AIwaysinstall a complete set , ,tainer,screw and,remove cover...

. .of new brushes. .2.. Remove.,t,he,through bolts, the, drive end•1:: •Removethe two throughbolts from the starter " ', .... housing, plunger'lever,.and the drive plunger

frame. ... lever.return spring.,brush_end :plate."Remove

•" ,,.2.,.::Remove the,brushend,-plate; brushsprings, ...... brushes,andJift out brushholder. ,•-.and brushes from the holder. .. _ .3.._Remove,the,;pivot pin,,retaining::the starter

.... 3: Removethe ground brushattaching screws or .. gear plunger lever., ', . ..... , ,'

' ..... ...rivets:fromtheframeand remove the brushes. '4. Removethea_matdf;e.÷lf,,thestarter;drive gear-.4. - .Cut -the insulated;brush leads from,the'field"- .,. ._/; assembly: is _'being_reused,;rem°vethe stop. . coils.as close to the fieldconnection point as ,.: . ring.from the end oLthe:armature, shaft, and

.possible... • remove the drive.5. Place the drive gear ,assembly on the new5. Check the plastic brush holder for cracks or

broken mounting pads. Replace if necessary, armature with a new stop ring.

6._:_.Positionthe new insulated field brushes lead 6"_ Install:the armatUre_in,thestarter_frame.• ,..on:the,field coil:connection. Position and . 7. ' Poston,:.the_drve;:gear:p unger;lever to the" ,,crimpthe-clip,provided with the •brushes to, .....frame"and'dr.ivegear,_assembly.

:hold the brush lead-to the connection. Solder• ,. thelead, clip,,and;connection together, using , 8.' Partiallyii'ltthe driyeendhousingbearing bore" _:withGrease ESB,M1Ci63Aor.equivalent (ap-

• ._ ' .a:300 wattiron.and, rosin core solder, proximately,I/4 fUll):Position,thedrive plunger..... 7. "Install the:ground brush ,leadsto the frame..... _lever,returnspring;,.the:drive end,.housing to

. : . ,with.the•attaching:screws or rivets.... •"the.starter frame.. Be_sure_.that..the.,stop,•ring. 8. .,Install brush holder and insert brushes in hold- _.,retainer .Js_;seated:properly: in,.the drive ....

er and install brush springs. Positive brush housing.leads should be positioned in their respective 9. Installbrush holder and insert brushes inhold-slots in the brush holder to prevent potential er and install brush springs. Positive brushgrounding, leadsshouldbe positionedin their respective

slots to prevent grounding..9. Install the brush end plate. Be sure end plate

insulator is positioned properly on the end 10. Install the brush end plate (be certain endplate, plateinsulatoris positionedproperlyon end

• 10. Install the two through bolts to the starter plate).frame and tighten to 6.21-8.47 N.m (55-75 in- 11. InstaLl the two through bolts to the starterIb). frameandtightento6.21-8.47N°m(55-75in-

11. Secure the:starter:in a',,Viseand._c0nnectthe'::: Ib). Install pivot pin.starter to a battery to check its operation. 12. Install starter drive plunger lever cover and

tighten retaining screw.13. Check the starter no-load current draw.

Page 502: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

'6-0"1 'GOVERNORS 6-01I

Part 6 --- Governors

SUBJECT PAGE _SUBJECT PAGE

_ DESCRIPTIONAND OPERATION........ .............. 6-01 . , .ADJUSTMENTS(Cont'd,)TROUBLESHOOTING ' • 6-02. RPM:Adjustments........................... ........... 6-03.ADJUSTMENTS No-LoadSurgeAdjustment................... 6-03

PreliminaryChecks............................. 6-02

DESCRIPTION AND OPERATION

.. ,.The4.9 liter.engineuseseithera:velocitygover-. , The governor is operated.bya combinationof.norora belt'driven mechanicalgovernor.• . manifoldvacuumand the air flow past the gover-

norvalve.The governorthrottlevalve is offset inVELOCITY GOVERNOR the throttle bore so that the combined force of

manifoldvacuum andthe_fuel,air flow.through the...The velocity governor is a single unit mounted . " bore_has!greater<effect,ontheJarger, upstream

,..between the carburetor and the intake manifold. .... area of.Zthe.valve._Thisforces the_throttlevalve to.... ,There isno provision for,repairof thisgovernor.lt : 'move, towardtheclosedpositionrestricting fuel-air', should be.replaced ,when damaged, flow; The:,;closingaction of:,the.throttle valve is

: opposed by thecontrol spring.,The control springis-attached:.to:the throttle, valve .shaft cam. The

1,,.cam providesa balance:betweenthe closing ac-

tion'.of;the:throttle,valve,:and,the action of the• control spring:at all,engine,speeds.

RPM . _, Underoperating conditions;,the goverfior throt-

ADJUS_f/ __ _/ tie valve does not close, but remains open enoughto allow the required quantity of the fuel-air mixtureto flow into the manifold to maintain the governedengine speed.

To maintain the proper vacuum to the distribu-tor, the governor has two interconnected vacuumtransfer ports and a vacuum transfer.plunger.When the carburetor throttle valve controls enginespeed, the orifice in the carburetor throat openingcontrols the spark advance the same as if it were

- _1_.,,,_ _.J_.. [_)-_ _._ not governor equipped.However,when the governorcontrols engine

speed vacuum produced below the governorSENSITIVITY throttleplatepullsthespark transfervalve, permit-ADJUSTMENT tingan openingfrom belowthe governorthrottle

platetothediaphragm.At thesametime the'trans-fer valve closes off the opening from the car-buretororifice.

Page 503: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

6-02 "_:_GOVERNORS ", 6-024, .. .' 0, _II ....

DESCRIPTION AND .......TROUBLESHOOTINGOPERATION (Continued)• ..... ,,

MECHANICAL GOVERNOR •,

MECHANICALGOVERNOR -- BELT,DRIVEN '_i:, To trouble'shoot a governor With afull load' ':,, surge, first increase the spread between full and "....

: ,Y;:Beltdriverxgovernors come in several versions, no-load. If this does not help, shorten the throttle:i;,Theconstant:,speed type is adjusted to operate at rod two or three turns. Then check for an exces- -_i_ '•_,!.._i:,onefixed sReed_ The gov,ernor_ spring_.is,_con- sively rich or lean fuel/air mixture at the carburetor. :,!mected between the spring lever and the speed Also look for vacuum leaks.

iadjusting lev_ir. Spring tension, thus engine rpm, There are two other conditions that can cause ___ .:'__'are adjusted;_by the •speed adjusting screw, this problem which should be checked. They are ':_' '"'_

_." The governor throttle lever has a flexible knee- excessively loose throttle rod ball joints or throttle_,_;actionlever w_'hichallows the engine to be idled at rod binding or rubbing. ;"

._,alower spe_ for starting and for standby service. No-load surge at maximum RP,M'can be elimi- :_:_-,i,The variable speed type al ows engine governor nated with the surge adjustment_r'ew providing•_ from idle to a maximum setting. The the no-load and full load is properly/set.

peed lever is actuated by the throttle Engine overspeed on accelerating can be•_cable,which in turn adjusts the spring tension and caused by excessive friction in the carburetor link-.-_i:_enginespee__ age, throttle shaft and/or accelerator pump, if so

" ' The throttLe,:isgenerally a solid arm, but in some equipped. The throttle rod may also be bending or;!_asesmayc_tainthe flexible knee-actionjointfor rubbing, or the drive belt(s) may be slipping.::•special applY'cations. These should be checked before making the

_ i-. The b_lt di_i,vengovernor must be driven by the adjustments.•,engine at a•if:i,xedratio. The governor pulley size If the engine overspeeds on removal of the load,

•and belt arrangement are determined by the en- try backing out the no-load surge adjustment

_,gine application and the speed at which it is to be screw one or two turns. If that doesn't correct the _!!i_governed. •_ problem, shorten the throttle rod two or three '..... turns. Also check for an excessive amount of oil in "

"-. Slippage in either of these_:,belts_would_,'permit the governor," the engine to run faster than the governor, thuspermitting overspeed of the engine. When the governor does not respond to load

changes, adjust the throttle rod to the properTightening the drive belt too tight can cause length. If problems still exist, back out the no-load

early failure of the governor bearings. The belt screw and adjust it per instructions.tension should be set to specification with a belttension gauge. Look for bent or fractured flyweights in the gov-

ernor possibly caused by insufficient lubrication oroverspeeding.

._ ADJUSTING NUT ADJUSTMENTS

"i!i;, XI- J' I!?PRELIMINARY CHECKS .... : ' " "_ . SPRINGf\

(_, • _ MECHANICAL GOVERNORS

Z Three preliminary checks must be made on the_._-_ mechanical governor before attempting any repair _';h._,HIGHSPEED adjustments. These are the governor oil level, _:_TOP SCREWS 'BB drive belt tension and the throttle control rod

;_ LOW SPEED '_. length. ,,_,

'.'_ F °

._.°

Page 504: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

6-03 GOVERNORS 6-03I IIIII

ADJUSTMENTS (Continued)

OilLevel SPREADADJUSTMENT

1 Removethe oilplug.If oildripsout the levelis,. full. If oildoesn't dripout,:removethe oil fill plug Proper.governoroperationrequiresa difference

and'add 10W-30,or10W-40.er_gineoil intothe fill between_full;Ioadand _n0-1oad;governedspeed.: " .hole until it starts dripping'out the'oil:level hole.' This"is :calledspread:or sensitivity. Too small an

Install the oil .level,and oil fill plugs. .-. RPM .spread between_thetwo:speeds will Cause.:governor:hunting and surging?Toolarge a,s_)l:ead"

Belt Tension .will-cause Iow_.response_t0a load...

........ ,.,_Belttensionishould, be checked ,ona cold belt, :-.. Thenormal_RPM:_speediis5.to,10percent. Thisonly. ' means_if,thedesired_f01l-'load,RPMJs2000 RPM,1 .... Install' the belt .tension tool on the drive belt " .the:,no_oad' RPM ca_n_i:be;2100Lto'2200RPM.

TI_ spr:e adjustm n iis the:eyeb yP.and check thetension. : .:_ el. ad_ e t ', oltt e..Ad-justment is madewiththeeyebolt thatattaches the2...If adjustment iSrequired,..Ioosenthegovernor,.

-, adjusting,boltsiand.move_ the:governor, unti ..: =spring.,tothe.variable speed lever.. the correct tension is obtained. To increase the spread, loosen the Iocknut and

3. Remove the gauge. Tighten the governor ad- turn the adjusting nut counterclockwise until thejusting, bolts. 'Install the tension gauge and . enginespeed decreasesapproximately 150RPM;

, recheck the belttension. .. '.,,then'..tighten_ithe:locknut....

' 'Throttle Control Rod :"_'_ Recheckigovernor,o'perationlunderfull load.andno,load :conditions, , :.. ; -.

1: _' ManualIymove".the governor-.throttle lever to" .. maximum open throttle with springtension on ' Todecrease thespread;Ioosen the Iocknut and

.... the governor. ' turn theadjusting_nutclockwiseuntil engine speed. ',,increases.approximately:;150 RPM. Tighten.the

2..._Check.thegap between the carburetor throttle ' Iocknut. •.... ; '

shaft lever .and.its:maximum :open ;position ' '.Recheck govemor,0peration:under_full.loadand._ _ _stop. It should be1/32 to,1/16 inch.wide:- -. " : ._no-load :conditions.,-:. __;", -. _ ' _- ', _..,: ;_'_"" "'_;.'

3.. If.adjustment is necessary, loosen the controlrod ball joint lock .nuts, remove the rod fromthe carburetor, throttle:lever and adjust the ilength of the rod with the ball joints.

4. Install the throttle control rod on the carburetorthrottle lever and recheck the gap. Tighten the Ilock nuts.

RPM ADJUSTMENT NO-LOAD SURGE ADJUSTMENT

One other adjustmentthat you may need toAttacha tachometerto the engine,then run the make is the no-loadsurgeadjustment.It is set at

engine until it reaches normal operating the factory and rarelyrequireschanging.If neces-temperature, sary,thisadjustmentcanbeusedto preventhunt-

Disengageengine loadand.loosenthe Iocknut ing and surgingat no-loadspeeds,providedtheon the governorhighspeed stopscrew.The Ioca- RPM spread adjustmentis setproperly.tionof thisscrewwillvary fromgovernortogover- To make the adjustment,:increasethe engine'nor. Slowly pull the throttle to the desired speedwiththehandthrottleto75 RPM lowerthanmaximumenginespeedandadjustthehighspeed the maximum no-loaddesiredcontrolRPM. Thenstop screwto maintainthisspeed, loosenthe no-loadsurgeadjustmentscrewlock-

The lowspeedadjustmentis madewiththe low nutandturnthescrewinwarduntilRPM increasesspeed adjustment screw, if the governor is so to the desiredcontrolRPM.

equipped,orwiththecarburetoridlespeedadjust- CAUTION: Do not turn the screw in all the way..... ment screw. Itwill Interfere with propergovernor operation

Movethe handthrottleorvariablespeedleverto and prevent the governor from returning thethe closedposition.Turn the adjustmentscrew in engine to idle speed.or out untilyou can maintainthe desired speed,

Page 505: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.-6-04 - _GOVERNORS _" 6-04 • '

ADJUSTMENTS (Continued) ,_ ..........

VELOCITY GOVERNOR ..........

, RPM Adjustment

:_.', Adjustment of the velocity governor is made To increase the engine RPM, turn the RPM ••_.;. with a tac_hometerattached and the engine at adjusting screw clockwise. ""-' _• _..... .._

': .:. normal operating temperature. To decrease the engine RPM, turn the RPM =''`_'', _._: _ Operate' the engine at wide open throttle and adjusting screw counterclockwise. ' ,_.

i::.: check the RPM .... ,:_..... _,

:::::_ii ....::_,"SENSITIVITY ADJUSTMENT "

The sensitivity of the governor has been set at' • If the governor • is not sharp enough, which:,_:_.the factory to cover a wide range of engine RPM.If causes too great a variation in speed between

the governor •control is too sharp or not sharp load and no load: turn sensitivity screw counterenough,.i.performthe following: clockwise 1/4turn at a time. It will be necessary

' " ":_" to turn the RPM adjusting screw clockwise ap-_-:_", Dnll we,lChplug covering sensitivity screwwitha proximately one turn for each 1/4 turn of the1/16"driil_Jnsert a 1/16"rod in drilled hole and pry

off welc_plug, sensitivity screw to bringthe RPM back to_'- normal.

• If gov_r, nor control is too sharp which causes, surging,or hunting: turn sensitivity screw clock- Seal sensitivity adjustment by inserting a brass

wise i74 turn at a time It w be necessary to lockwasher into the hole engaging tang of washerturnRP_M intoslot in adjustingscrew. Insertnewwelch plug..... adjusting screw counterclockwise ap-

!._!i proxim, tely one turn for every 1/4 turn of the and tap lightly, using a flat punch• '

:i',:;_ _. sensitivity screw to bring•the RPM back to CAUTION: Too sharp a blow against welchi,_ normaU_......... ' __'__ ' ' plug may upset sensitivity adjustment.

Page 506: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

7-01 COOLING 7-01• II IIR

Part7 •Cooling

' SUBJECT ' 'PAGE • SUBJECT PAGE

. ,DESCRIPTIONANDOPERATION ,.".. ........ 7-01 ...... ADJUSTMENTS:.' ....

TESTING DriveBelt.......... ...... _..:,.. -,,,'_. .; ...: .:. '::..:: '7-03......... Pressure.Test.................................................. 7.02,.. "BeltTension........ : .......... .... ...; ........ 7-03

, . ' ,.ThermostatTest _:._,,:. ............. •............ 7-03, ,.CLEANING;ANDINSPECTIONI.........:,:,...,.. .... 7-04

.. . , . . • .., ., .-

'DESCRIPTION AND OPERATION • ................

.... • Thecoolingsystemhas_twostagesof operaton._. •J• For themosteffectivecoolingsystemoperation, •.and,usesonethermostat.In stageone the coolant thismixturestrengthshouldbe maintainedallyearflow is restricted for minimum circulation through round and in all climates.

the engine. In the.second stage the thermostat . All.coolanL:added_:sbould_be.the_:specifiedmix--.. opens and.permits coolant flow through the radi- •ator to maintain proper-operating.temperaturesl _ .... tureo[;_FordPermarledt'_..Anti_Freez'ela.ndwater If

' • , ' __Ford PermanentAntiiFreeze'.is.not:a_,ailable,an-' ' "other.reputable,permanenL,anti-freeze may

, _ : ,___'.... :,:used,and::dilutedwith.an:equalamount of...watbre• i":_(_ • "-_ _... :Ordinarytapwatermay_beusedinariemergen-

'[ II Ii : If If _r" • ..- cyexceptinareasthatwater:isknown:tobeexcep-r_. 1 u II II I ' I/ " . tionally hardor to;haven highaika Content The

l.] '._ ^_' ' ^ .,,_ ,, L. , S ...,_'_":.."cooling s_'stemishouldbedrainedan'dflushecl.and ': [ 'I'L_'_-I_ _ '_"-- _-'_" "_""-- ;_'_PI!I. ....'thepropermlxtUreofanti-freezeaddedassoon_ias:,*.:

V_J_--_I_,,_J,-_J . possible; however. ' ' '_r-'_1_I£ ,'j° ""L____. _ _-_,_-_" o _ o_r_l_ To avoid possible overheating in very hot_---_"_ ::.... o _-J ![l_] weather, do not use mixtures of more than 50

/_-'_,j_,_,.J __o _",_ ",/'_/_l _-- L_II percent anti-freeze except in areas where anti-I I I%r _ _''--V/ u _ _ u_ freeze protection below -35 degrees F is re-

I I L__._I quired. In this case, refer to the coolant mixtureL./' [ _ I _] chart on the Ford Permanent Anti-Freeze

I_ L.-,I 411 container.

"'" _"_ _111 A standard ethylene glycol hydrometer can be\ . __.j.. IIJ used to check the protection level of the long-life

coolant.A2274-1B

To preventdamage to thecoolingsystem dur-COOLANT ing periods of below freezing ambient tem-

perature,whenwater oranti-freeze is added to theCorrect coolant level is essential for maximum supply tank, always operate the engine at fast idle

circulation and adequate cooling. In addition, for for 30 minutes before letting the engine set in thethe cooling system to perform its function, it must Off positionfor prolonged periods. This will allowareceive proper care. This includes keeping the uniform mixture throughout the cooling systemradiator fins,clean and aperiodic inspection of the - and prevent damage by freezing,,when sufficientcooling system for leakage, anti-freeze is used.

Use care when•removing the radiator cap to DRAINING AND FILLING THE SYSTEM

avoidinjuryfrom escapingsteam or.hot water. Topreventlossof anti-freezewhendrainingtheWhenthecoolingsystemis drained,filltheradi- radiator,attach a hose to the radiatordrain cock

atorwith specified ,coolant.The coolingsystem is anddrainthecoolantfromthe radiatorintoa cleanfilledwitha 50-50 solutionof FordPermanentAnti- container.Freeze and water which prevents corrosion, To drainthe radiator,open the drain cock Io-keeps the cooling system clean, provides anti- caredatthe bottomof the radiatorandremovethefreeze protectionto - 35 degrees F inwinter and radiatororsupplytank cap. The cylinderblockisprovides for higher summer operation drainedby removingthe drain plugs locatedontemperatures, bothsidesof the block.

Page 507: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

7:-02 ._COOLING, 7-02 - . .I I ....

DESCRIPTION.AND OPERATION (Contlnued)-.

,.block .drain-plug(s) and close the radiatordrain .... displacement of entrapped'air. Refill radiator as--:.. cock. :,,: required. : ._;/_. After the!initial fill, coolant level will drop approx- ._._.

.; - ' imatly 1quart after the engine has been operated .... :_

TESTING ....:

•..'_.__PRESSURE TEST container. Discontinue pumping when bub- :.:._:_'"_"_"" _" bles appear, r:

It is recommended that a cooling system pres- _._sure test.!gauge be used to properly test the When the bubbles cease, read;.the pressure

• systemfor: gauge. The gauge reading isi!:thepressure""__""" ".... relief of the cap and should be_i_thin specifi-,.._..,:• Blown or leaking cooling system gaskets.-, cations. If the pressure readin_i:exceeds the

• Internal or external cooling leakage, specified limit, replace the radiator cap.• Pressure cap malfunction.

,;;_- ::.:L_. 7. If bubbles continue and the pressure drops_.:i.:' Some.-_0dification of existing pressure testers below 10 psi for engines with a 13 psi system,:'i- may be-.ir_e:'quiredin order to use this procedure, or below 5 psi for a 7 psi system, the radiator

1. Shut ;the engine off. To prevent loss of capis not holding pressure. Release pressure::. coolant and to avoid the danger of being and wash cap in clean water to dislodge any

burned, place a cloth over the cap and fo=:eignmatter from the valves. Check the rub-.r- rotatb' the cap slowly counterclockwise to ber sealing surface of the cap and also the cap;_i firststop to allow pressure ro escape com- sealing surface in the radiator neck. Inspect.:.::, plete!y. Then, turn cap again slowly coun- the cam lock flanges on both sides of the filler..,;..:, terclockwlse to remove, neck for maximum cap engagement. ._.

"' 2. After;'ihe cooling system pre'ssure has been 8. Re-check the cooling system as outlined in' released, remove the radiator cap, wet the Step 6. If the cap still does not hold pressure,

rubber sealing surface and re-install cap tight- the cap is damaged and must be replaced.ly on the radiator. Recheck system after a new cap is installed to

assure that the system will now hold pressure.3. Disconnect the electrical.connector from the

engine temperature sending unit and remove 9. If the bubbles in the water container ceasethe temperature sending unit from the block, and the radiator cap is within pressure specifi-

cations, observe gauge reading for approx-With the radiator cap installed, only a small imately two minutes. Pressure should notamount of coolant will be lost when the.send- drop during this time. :_.,.

ing unit is removed. 10. If pressure drops, check for leal_:_,:atengine to4. Install an adaptor fitting tightly (3/8 N.P.T. radiator hoses, by-pass hos_.:.thermostat

male thread on one end, and a hose connec- housing gasket, etc. Any leaks which are• .._..- tion on the other end to accommodate the found must be corrected and the system re-

tester hose) in place of the sending unit. checked.

._,_'5. Remove the radiator overflow hose from the _il. If the system holds pressure,,remove the radi- '_ ,_: retainer clips. Make sure the hose is firmly ator cap to release the pressure; then, re-...... installed on the radiator overflow tube and install the cap.;_.- is in good condition. Insert the free end of :._,_. the overflow hose into a container of water. 12. Remove the adapter and reinstall the tem- ..

perature sending unit. Check coolant level6. Attach the pressure pump and gauge to the and replenish, if necessary, with the correct

adapter fitting and pressurize the cooling sys- ': coolant solution.-tom until bubbles are observed in the water

Page 508: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

"7-03 COOLING 7.03:IIl IIII

,TESTING (Continued)

THERMOSTAT •TEST

' It is good.practice to test new thermostats be-." age. This may be done by holding the thermostat' , ,fore installing,them inthe engine. , . ,._uptoa, lightedbackground.'Lightleakage around

..... • • Remove.the,thermostat,and immerse'it in boil- _ +•the:.thermostat,valve:(thermostat, at :.room.tem-• . ............... perature); is+unacceptab e' and mthe _thermostat '

• _•-,•mg water..H.eplace,t.ne;mermostat, ir it ,ooes,not ' . should be replaced, :lt_is;possible.,onsome ther-'

open more man 1/4 mcn. . . mostats, thataslight•leakage of:light at one or two• +,: .. ,_+If the problem,being:investigated is insufficient:......+•locations_:on_,the.,perimeter(of:,the,,:valvermay be

...... ' +..heat. the,thermostat shou d be checked for,,oak-, ,' :,detec:bed,:_+This:_s.sh0uldybe+:c0nsidered.normal..

, , + +

ADJUSTMENTS. . . , , . , • : ..

:DRIVE BELT._ ' ' THERMOSTAT.REPLACEMENT .

The fan drive belt shouldbe properly adjusted at Do ,not attempt to repair the thermostat. It• • all times. A loose drive.belt can .cause improper should_be,replaced.lf it,.is not operating prop

.. - : '-alternator;fan and.waterpumpoperation,'A belt .... :._erly..CheCk;_the_thetmostat;beforeiinstallingit,-, :, that.is too tight places a severe,strain on the water..,., following,.the+_:procedure.under_,,Thermostat

•:.pump and alternator bearings. .. ' Testing.

..:_• - Aproperly tensioned drive belt.minimizes,noise ' ,Removal _. " " ""- " " • " ". ' • '•.+ ands'also prolongs the•?service life of,the belt, , ....•, ' ..,Therefore.,.it'is'recommended-that a,belt,,.tension -_",1: •_Drain;the,radiat0rs0:that .thecoolant level.is

-• ,gauge .be used ,to.check and adjust the belt ten- ,_ below.the thermostat.....' sion.,Any:belt;that+,has-been:operatedfor_a : 2,. _Rembve,_,the_water+,outlet:housing.retaining

.......... •! minimumof+10 minutes•Js;considered.a, used;-,:.-: :+,,:bolts:_,Bendthe,_radiator,upperhose(Jpwards.,_.. rp

..... '...... .,,_belt, and whenadJusted, it,must beadjusted to ..... , ,:_,:and_remove,the;therfnostat+iand:gasket.- . ' ,,the tension shown In the specifications.

Installation

BELT TENSION 1, Clean the water outlet housing gasket sur-faces. Coat a newwater outlet housing gasket

1. install the belt tension tool on the drive belt with water-resistant sealer. Position the waterand check the tension, outlet housing gasket to the head opening.

2. If adjustment is necessary_ loosen the alter- 2. Install the thermostat in the water outlet open°nator mounting bolts and move the alternator • ing with the copper pellet or element towardadjusting arm bolts. Move the alternator to- the engine and the thermostat flange posi-wards or away fromthe_Jengiqeuntil.:thecor-rect tension is+0btained:_Rem0ve"thegauge.: i'_',,tioned in the recess: If the thermostat is im-• ,. _ .;,, properly installed, it,will cause a retarded flow.... : ,+ •

BELT TENSION / of coolant.

3. Position the water outlet housing against thehead. install and torque the retaining bolts tospecifications.

_'k\ _ 4. Fillandbleedthecoolingsystem.Operatethe

engine until normal operating temperature isreached: then check the coolant level andcheck for leaks.

01039-1E

Page 509: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

7.4)4; _ "•':::_COOLING? 74)4';'

CLEANING AND INSPECTION ..........r ,

COOLING• SYSTEM "

": , :_To.remo_erust,;sludge.andother.,foreign:mate-.;'..-.: *.Varioustypes,of flushing.equipment.areavail..... , : ' /_':_'J:.i: rial from.tHecooling system, use either FoMoCo 'able. If pressureflLJ'shingis used, make surethe Y::• :' Regular,C_oling System Cleanser or in severe cylinder head boltsare properly tightenedto pre- ',;,_,• ,.. casesuse_HeavyDuty Cleanser. Removalofsuch vent possible water leakage into the cylinders. ,,::'_ .Ji. "

., material iestores cooling efficiency and avoids Always remove the thermostat prior to pres-overheating.:. . ...... sure flushing. _.

..,_ Inseve_,ercaseswhere cleaning solventswill not A pulsating or reversed direction of flushing _ :r_;'__ _''_

...._'_'properly _l'eanthe cooling systemfor efficientop- • water flow will loosen sediment more quickly _,"._;:" eration, i!k,willbe necessary to use the pressure than a steady flow in the normal direction of _*•..:i',._flushing /_ethod. coolant flow. _ .

; r.

• ,.

' >:'2 "'# *

Page 510: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

8-01 SPECIRCATIONS 8-O1II i I I

. Part 8 ---Specifications

• ,GENERAL SPECIFICATIONS ' . : • , .' VALVEiMECHANISM (Cont'd.) '. "

Bore and Stroke .................... 4:00 x 3.98 Collapsed Tappet Gap " ""• ,Firing Order.., ........ : .............. ,. .... 1-5-3-6-2-4 , ,Allowable :....... ............... 0.100-0.200.. Idle Speed (rpm) " 500-550 Desired ........ ' .... :.... ................ 125-,175

................. CYLINDER HEAD • CAMSHAFT AND,TIMING .GEARS

_' Gasket Surface Flatness ................. 0;006 inch , Camshaft'Journat,_Diameter---, ,..... ,in any 6 .inches Standard., .................................. '. 2.017-2.018

, :or 0.007, inch overall " Camshaft,,Jeurnal:Runout ..... .'..,.,..,.;_.:_.-...... . 0.008.... ;, ,Valve Guide Bore Diameter ,. ' . 0:3433-0:3443 _. Camshaft",,Journal,_loi:Bearing " .,_,.-,

' .Valve Seat Width 4- " .. . Cleararlce i _/..ii ."_,i,.:.... i.. _...i: .' .0.001-0.003Intake ..................... :... _ ,0.060-0.080 .. Wear Limit ........................... 0.006Exhaust .............................. 0.070-0.090 Camshaft Journal Out-of-Round ......... 0.0005

Valve Seat Angle 45 ° Camshaft End Play ................ 0.001-0.007Valve Seat Runout ............... 0.0015-0.002 Wear Limit ........................... 0.009• o .

,VALVE MECHANISM Camshaft Gear, to.,Crankshaft....... . .Gear,Backlash ......................... ..:... ,0.004-0.010

," Valve ,Stem Diameter --. Standard Camshaft:Lobe Lift. .. Intake and Exhaust ......... ..... •0.3416-0.3423 Intake ...................... .... ...... O.247-0.249.Valve,:Stem• Diameter ---.003 Oversize Exhaust 0.247-0.249

,, Intake-and Exhaust ' 0.3446-0.3453 Maximum, Allowable Lobe.Lift.Loss ....... 0.005Valve, Stem ,Diameter -- .015 ,Oversize ,_ ,Assembled.Gear, Face_Runout _

, Intake andExhaust .............. 0.3566-0.3573 , • Maximum ............................... 0.005.Valve Stem Diameter.--:.030,Oversize _ Inside Diameter ................... 2:0190-2.0200, Intake, and, Exhaust ........... ........ 0.3716_0.3723 ,Location'_,in.,Relation to.Front. Face ,of. Block

' o ' '

Valve Face Angle .............. •................ 44., Cam, Bearing Bore" Face,,m No",_1Bearing :. :Valve Stem to'Valve Guide Clearance Only _ Below 0.020-0.035

Intake and Exhaust ............ 0.0010-0.0027 .................Wear Limit ........................ 0.0055 CRANKSHAFT

Valve Head Diameter Main Bearing Journal Diameter ,., 2,3982-2.3990Intake .......................... 1.772-1.790 Main Bearing Journal Runout ............ 0.002Exhaust 1.551-1.569 Wear Limit ........................... 0.005

Valve Face Runout .................... 0.0020 Connecting Rod and Main Bearing JournalsValve Spring Assembled Height Out-of-Round m Maximum " 0.0006

Intake ............................ 1.61-1.67 Connecting Rod and Main Bearing JournalsExhaust .......................... 1.44-1.50 Taper _ Maximum Per Inch .......... 0.0005

Valve Spring Free Length,_ Approximate .... : Thrust Bearing Journal Length ....... 1.199-1.201Intake ................................ 1.96 Main Bearing Journal Thrust FaceExhaust ................................ 1.78 Runout .............................. 0.001

Valve Out of Square -- Maximum .. 5/64 (0.078) Connecting Rod JournalValve Spring Pressure- Lbs. Diameter ..................... 2.1228-2.1236

@ Specified Length Crankshaft Free End Play .......... 0.004-0.008Intake ....................... 66-74 @ 1.640 Wear Limit ........................... 0.012Wear Limit ............ 10% Loss of Pressure Assembled Gear Face Runout " 0.003Intake ...................... 166-184 @ 1.240 Main Bearings to Journal Clearance

Wear Limit .......... 10% Loss of Pressure Desired ...................... 0o0008-0.0015Exhaust ...................... 66-74 @ 1.470 Allowable . ................... 0.0010-0.0028

Wear Limit .......... 10% Loss of Pressure Crankshaft to Rear Face of Block RunoutExhaust ................... 166-184 _' 1.070 TIR Max ............................. 0.005

Wear Limit .......... 10% Loss of Pressure Flywheel Ring Gear Lateral RunoutHydraulic Valve Lifter Leak Standard Transmission ................ 0.040

Down Rate _ Seconds ................ 10-50 Automatic Transmission ............... 0.060Valve Push Rod Runout _ Maximum ..... 0.015 Flywheel Clutch Face RunoutValve Tappet Diameter _ Maximum ............................ 0.010

Standard ..................... 0.8740-0.8745 CONNECTING RODValve Tappet to Tappet Bore

Clearance ....................... 0007-.0027 Piston Pin Bushing IDWear Limit .......................... 0.0050 Standard .......... : ......... , 0.9734-0.9742

Page 511: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

8-02 :SPECIFICATIONS 8-02III I II ":-" II I

SPECIFICATIONS (Continued)

CONNECTING ROD (Cont'd.) CYLINDER BLOCK _

,.Bearing Bore Diameter. ......... 2.2750-2.2758 • Cylinder Bore Diameter • 4.0000-4.0048 .... _,-Bearing Bore OLJt-of-Round ............. 0.0006 Cylinder BoreOut-of-Round _J"!i....'_Bearing Ta_er 0.0004 Maximum 0.0015 ......,,. .. ,,, o, ............ *,., o ......... , .... , ...... ° ........ ; ____

' _Connectin_iVRod Length -- Wear Limit ........................ 0.0050,_ Center toCenter .............. 6.2082-6.2112 Cylinder Bore Taper ................... 0.001 ,,Zwist Total!Difference -- Maximum*, ...... 0.024 Wear Limit ......................... 0.010,Bend Total Difference -- MaximUm" ...'... 0.012 Main Bearing Bore Diameter ... 2.5902-2.5910 '

:__Connecting_Rod.._,Assembly -- Assembled to , Head Gasket Surface ---_ ..... " ...._:._i:Crankshatt Side Clearance,. ...... 0.006-0.013 Flatness ........ 0.003 inch.in any 6 inches i-'

Wear Umit ......................... 0.018 or 0.007 inch overall",_in bushing_and crankshaft bearing bore must be Cylinder Tappet Bore _'_=_i l_arallel and-_i_ithe same vertical plane within the Diameter ........ -........... _:0.8752-0.8767 '_......._......... _"__pecified total difference at ends of 8-inch long bar Distributor Shaft Bearing Bore • '_" ',.-.',_easured 4 inches on each side of rod. Diameter ............... ,_ ,:_:_'0_.5!'55-0:5165i Connecting Rod Bearings toCrankshaft Cylinder Bore Surface Finish RMS_ .-_..... 15-35'_ Clearance Camshaft Bearing Bore .......... 2.019-2.020£_,_.Desired ...................... 0.0008-0.0015 OIL PUMP

Allowable .................... 0.0007-0.0024Oil Pressure _ Hot @ 2000 rpm ......... 35-60

PISTON Relief Valve Spring TensioniPiston Di,4_eter Lbs. @ Specified

, " Coded Red .................. 3.9982-3.9988 Length ................. 20.6-22.6 @ 2.490• Coded Blue .................. 3.9994-4.0000 Relief Valve Clearance .......... 0.0015-0.0030,, 0.003 Oversize ............... 4.0008-4.0014 Drive Shaft to Housing Bearing

o;:Piston Pin Bore Diameter ....... . 0.9754-0.9757 Clearance .................... 0.0015-0.0030 _..,_piston to Bore Clearance" . ....... 0.0010-0.0018 Rotor Assembly End Clearance _ ,,__,'Measured:_90° to pin centerline and at pin _ Pump Assembled ............. 0.0011-0.0040_,centerline:height. • Inner to Outer Rotor TIC Clearance _ _ii_:_Piston PinVDiameter " • " ""_" _ -_ _ Max. " 0.012 '_:i: Standard ..................... 0.9749-0,9754 (with feeler gauge inserted 1/2 inch min. and iPiston Pin Length ................. 3.150-3.170 rotor removed from pump housing).Piston Pin to Piston Outer Race to Housing _ Radial

Clearance .................... 0.0002-0.0004 Clearance ...................... 0.001-0.013Wear Limit .. ...... . ................. 0.0008 Oil Capacity (Qts.) (Add 1 qt.

Piston Pin to Connecting Rod for filter change) .......................... 6Bushing Clearance Interference Fit IGNITION SYSTEM

Piston Ring Groove WidthTop ......................... 0.0800_0.0810 Ignition Timing _ B.T.D.C.Bottom ....................... 0.0800-0.0810 Recommended .............. ._,q_:_v._.......... 6°Oil ........................... 0.1880-0.1890 Coil •-__._!_:'-_-

Primary Resistance __-""PISTON RINGS (Ohms) .................. ,i_i5-1.25 (75°F.)

Compression Ring Width Secondary Resistance' Top ........ 0.0774-0.0781 ........, (Ohms) ................. 7700-10500 (75°F.)

"i_ Bottom .................. 0.0770-0.0780 •,.Amperage Draw ",,:._pmpression Ring Side Clearance Engine Stopped 4 ,_:::_!Top ......................... 0,0019-0,0036 Engine Idling ........................... 5._._Bottom ...................... 0.0020-0.0040 Ballast Resistor (Ohms) ........ 0.8-1.6 (75°F.) ,,_' Compression Ring Side Clearance _ Stator Assembly Resistance

Wear Limit .......................... 0.0060 (Ohms) ......................... 400-1000,Oil Ring Side Clearance .................. Snug Spark Plug Gap (Inches) .............. 0.045,.Compression Ring -- Standard Bore _ _.,, '...... _."__,,RingGap Width,,_Top ............................ 0.010-0.020:/Bottom ......................... 0.010-0.020

,_Oil Ring _ Standard Bore _ _:- '_._aing Gap Width ............. _,'i.. 0.015-0.055

Page 512: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

8-03 SPECIRCATIONS . 8-03Ill I I

SPECIFICATIONS (Continued)

•, DISTRIBUTOR.ADVANCE CHARACTERISTICS• " CENTRIFUGAL ADVANCE. Set the test stand to 0° at 250 rpm and 0 inches of vacuum.

rpm Advance .. . Vacuum "

.... (Olatrlbutor) ' , (Degrees) , • " '=, :: ,.," .':-(Inchesof Mercury)-600 0:2 0800 3-5 0

1200 6-8 ' " ' 01600 6-8 112 : . 0 ._ ''2000 6-8.3/4 . . 0 '

, VACUUM.ADVANCE.- Set the. test stand to0°_atl000 rprn and O.:inches;of,:vacuum-- " " ,.........

. - -rpm - Advance --: ':",, ', ;...= , ..,.,:':,...Vacuum ''. (Olstrlbutor) . . • (Degrees) ' ..... (Inches'of Mercury)

i000: "" :. 4 !/2"7 1/2 " 81000 " ..... '" ' 6-8 3/4 ' 101000 8 3/4-111/4 14

.... . , - ,..: ,

..........: ........:.,_ FUEL PUMP. --.MECHANICAL .BELT.TENSION ' ...... ' .

•.Static Pressure (psi)* . ......................... ,5-7. _ Belt Tensionr ._'_.'._AIl::Except Governor • ::• : Eccentric Total ,Lift (Inch) .... '............. 290;:310 . .,.New ........ ..., ........................... 140

, Volume Flow - Minimum* ;...l.Pt. in 20 seconds . .Used ......... .. i .....".... ' ....... : ............ 110•-Inside diameter, of smallest passage in test flow , Governor 'circuit must not be less than 0.220 inch.) ', New ..... :.. ..... ............................... 70• "(On engine..with:temperatures.normalized;.and • .,.:,.Used................ ; ........................... 50:. atnormal, idle speed,- in .neutral.) , . :,A usedbelt:is ones,that has beenin_operatioh f0r ....

THERMOSTAT • 10 minutes or more.

Begins to Open (°F) .................... 157-164Fully Open (°F) ........................... 186

POSITIVEENGAGEMENT STARTER

Positive Engagement Starter Motor Starter Brushes'1 Through

Normal Current Mfg. Wear Spring Bolt MountingCurrent Draw _- : Engine, Draw Length = Limit Tension Torque Bolt TorqueDla. Under Normal' Cranking _ No. N-m

mm mm: kg N.mmm (inches) Load (Amps) Speedi; , Load (inches). (inches) (Ounces) (In-lbs) (ft-lbs)(rpm) (Amps)

12.2 6.35 1.134 6.21-8.47 21-27101.60 (4) 150-200 180-250 70:. (0.50) (0.25) (40) (55-75) (15-20)

12.2 6.35 1.134 6.21-6.47 21-27114.30 (4.5) 150-180 " 150-290 80(0.50) (0125) (40) (55-75) (I 5-20)

MaximumCommutator runout is 0.1270mm (0.005 inch)• Maximum starting circuit voltage drop (battery positive terminal to starter terminal) at normal enginetemperature is 0.5 volt.

ALTERNATOR

Slip-RingTurning BrushLength PulleyRating Field mm (inches) mm (inches) Nut Belt TensionCurrent*

Amperes Watts Amps @ 12V MIn, Max. New Wear Torque@ 15V @ 12V Dla. Runout Limit N.m (Ft-Lb) N (Lb)

...... 40 600 4.25 31 (1.22) .0127 (0.0005) 12.19 (.480) .6.35 (1/4) 82-135 (60-100) 311-489 . (70-110) j

60 900 4.25 31 (1.22) .0127 (0.0005) 12.19 (.480) ' 6.35 (1/4) 82-135 (60-100) 311-489 . (70-110)

_For belt tension specifications, refer to Section 27-06 AccessoryDdve Belts in the Engine Shop Manual."A field current of 4 amps is used with.solid-state regulator.

Page 513: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

8-04 SPECIFICATIONS 8-04

SPECIFICATIONS (Continued)

TORQUE SPECIFICATIONS

Torque TorqueItem Item

N.m ft-lbs N.m f1-1bs

ConnectingRod Nut 55-61 40-45 Valve Push Rod -- Cover to CylinderBlock 2.8-3.9 (25-35 in-lbs)

Cylinder Front Cover 17-24 12-18 Water Outlet Housing 17-24 12-18/

Cylinder Head Bolts (_) (_ Water Pump to Block,_FrontCover 17-24 12-18

Damper to Crankshaft . 177-203, , 130-150 AlternatorBracket to CylinderBlock -- Bolt 41-61 30-45

Flywheelto Crankshaft 102;115 75-85 AlternatorAdjusting Arm to Cylinder Block

Main BearingCap Bolts 82-94 60-70 Bolt 26-36 19-27

Manifoldsto CylinderHead_ 30-43 22-32 AlternatorAdjustingArm to Alternator Bolt 33-54 24-40

Oil FilterInsert to Cylinder Block/Adaptor 20-48 15-35 Carburetor Attaching Nuts 17-20 12-15

Oil FilterAdaptor to CylinderBlock 55-67 40-50 Camshaft Thrust Plate to Cylinder Block 16-24 12-18Fuel Pump to Cylinder Block;Front Cover 17-24 12-18Oil Filter to Adaptor or Cylinder Block 1/2 turn after gasket

contacts sealing surface Carburetor Mounting Stud 7-13 5-10

-- oiled gasket Distributor Clampdown 24-33 17-25

Oil InletTube to Pump 14-20 10-15 Intake Manifold Vacuum Fittings 8-13 6-10

Oil Pan Drain Plug 21-33 15-25 Pressure Plate and Cover Assy. to Flywheel 16-25 12-18

Oil Pan to Cylinder Block 14-17 10-12 Fuel Line Nuts 20-25 15-18

Oil Pump to Cylinder Block 14-20 10-12 Item N.m As Noted

Oil InletTube to Main BearingCap 30-43 22-32 DistributorHolddown Bolt 23-34 17-25 ft-lbs

Pulleyto Damper Bolt 48-67 35-50 DistributorAdaptor to DistributorBase 2-2.5 18-23 in-lbs

RockerArm Bolt 24-31 17-23 Stator Assy. Lower Plate Assy. to DistributorSpark Plug to Cylinder Head 14-20 10-15 Base 1.7 rain. I5 in-lbs(rain.)

Valve RockerArm Cover 7.9-11.9 70-105 in-lbs) Diaphragm Assemblyto DistributorBase 1.7 min. 15 in-lbs(rain.}

Spark Plug to Cylinder Head 20-27 15-20 ft-lbs

(_Progressively increase the tightness in three steps using this sequence:1ststep -- tighten all bolts to67-75 N.m (50-55 ft-lb)2ndstep -- tighten atl bolts to 82-88 N.m (60-65 ft-lb)3rd step -- tighten all bolts to 94-115 N.m (70-85 ft-lb)

(_Follow bolt tightening sequence in Part 1.

- SPECIAL SERVICE TOOLS

Tooi Number Description Tool Number Description

T50T-100-A ImpactSlide Hammer T58P-6316-D CrankshaftDamperRemover

T59L-100-B ImpactSlide Hammer T82T-6256-A Camshaft Gear Remover

T58L-101-A PullerAttachment TOOL-6331-E UpperMain BearingInsertRemover& Replacer

D78P-4201-B Dial IndicatorMag. Base T74P-6375-A Flywheel HoldingTool

TOOL-4201-C Dial Indicator With Bracketry T70P-6513-A Tappet Bleed Down Wrench

T70P-6000 Engine Lifting Bracket TOOL-6513-ABA Valve Holdup Air Adaptor

T64L-6011-EA Cylinder Ridge Reamer i TOOL-6513-DD Valve Spring Tester

T73L-6011-A Cylinder Hone Set T62F-6565-A Valve Spring Compressor

T61P-6019-B FrontCover Aligner _, _ TOOL-6565-AB Cup Shaped Adaptor

T68P-6135-A Piston Pin Remover/Replacer • T73L-6600-A Pressure Gauge

TStP-6135-A Piston Pin Remover/Replacer Adaptors ' T82L-12270-A Distributor Wrench

D79L-6250-A Heavy Duty Reversible Ratchet - T74P-6666-A Spark Plug Wire Remover

D79L-6250-B Ratchet Handle T75L-6666-A Plug Boot Installation Tool

D79L-6250-C Ratchet Adaptor T65P-6701-A Rear Oil Seal Replacer

D79L-6250-D Ratchet Adaptor " D79L-6731-A Oil Filter Wrench

T65L-6250-A Camshaft Bearing Set T74P-7137-A Pilot Bearing Replacer

T65L-6306-A Camshaft Gear Replacing Adaptor T63L-8620-A Belt Tension Gauge ......

T52L-6306-AEE Crankshaft Damper Replacer T65P-10300-B Alternator Pulley Remover

Page 514: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

C-6AUTOMATIC

TRANSMISSIONThe Source for Power...

WorldwiderM SERVICEMANUAL

Page 515: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

..... INTRODUCTION., ,.,- J"

Important Safety NoticeAppropriate service methods and proper repair procedures are essential for the safe, reliableoperation of all motor vehicles as well as the personal safety of thehndi.vidualdoing the work.This Service Manual provides general directions for accomplishingservice and repair workwith tested, effective techniques. Following them will help assure reliability.

There are numerous variations in .procedures, techniques, tools, and parts for.servicingvehicles, as well as in the skill of the-individual doing the work. This Manual cannot possiblyanticipate all such variations and provide advice or cautions as to each. Accordingly. anyonewho departs from the instructions provided in this Manual must first establish that hecompromises neither his personal safety nor the _,-ehicleintegrity by his choice of methods.tools or parts.

Notes, Cautions, and WarningsAs you read through the procedures, you _ill come acros,; NOTES, CAUTIONS, and WARNINGS.Each one is there for a specific purpose. NOTES give you added information that will help you tocomplete a particular procedure. CAUTIONS are given to prevent you from making an error thatcould damage the vehicle. WARNINGS remind you to be especially careful in those areas wherecarelessness can cause you personal injury. The following list contains some general WARNINGSthat you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the vehicle.

• Be sure that the ignition s_vitchis always inthe OFF position, unless otherwise required by theprocedure.

• Set the parking brake when working on the vehicle. If )ou have an automatic transmission orautomatic transaxlc, set it in PARK unless instructed otherv, ise for a specific operation, if youhave a manual transmission or manual transaxle, it should be in REVERSE (engine OFF) orNEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks(4" x 4" or larger) against the front and rear surfaces of the tires to provide further restraintfrom inadvertent vehicle movement.

• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.

• Keep yourself and your clothing away from moving parts _hen the engine is running, especiallythe drive belts.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaustmanifold, tail pipe, three-way catalytic converter and muffler.

• Do not smoke while working on a vehicle.

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing beforebeginning to work on a vehicle.

• If it is necessary to work under the hood. keep hands and other objects clear of the radiator fanblades! Your vehicle may be equipped with a cooling fan that may turn on, even though theignition switch is in the OFF position. For this reason care should be taken to ensure that theradiator electric motor is completely disconnected when working under the hood when engine isnot running.

Page 516: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

: C-6 AUTOMATIC TRANSMISSION ,,b

SERVICE MANUAL

• This manual represents service information for the:;' C-6 automatic transmission that is the same as thes, Ford light truck transmission with the exception of

the rear extension as illustrated below. ........., _,', ,. ,

378475 STUD

7086 GASKET

7A452 BEARING7085 RETAINER

%,33846 NUT

7A040 t--XTt-NSION j........................ 386755 " -

SNAP RING 0'_

...... ?

C-6 AUTOMATIC TRANSMISSION 7048 SEAL

Power Products Division• Geometric Results Incorporated

28333,Telegraph Road " .-The Source for Power... Southfield, M! 48034

Worldwide r._,

Page 517: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B- 1 Transmission, Automatic, C6 07-01B- 1

-.- SECTION.,O.7'O1BTransmission,Automatic,C6 ................

SUBJECT PAGE SUBJECT PAGE

VEHICLE APPLICATION ........................................... 07-01B-1 DISASSEMBLYDESCRIPTION Transmission ..................................................... O7-O1B-33

C6 Transmission .................................................. O7-01B-2 DISASSEMBLYAND ASSEMBLY OFTransmission Identification .......................... ; ...... 07-01B-2 SUBASSEMBLIES

OPERATION ............................................................ 07-01B-7 Direct Clutch .......................................... . .......... O7-O1B-44DIAGNOSIS AND TESTING Downshift and Manual Linkage .............. : ........... O7-O1B-53

Air Pressure Tests ............................................. O7-O 1B-26 Forward Clutch .................................................. O7-O 1B-46Engine Idle Speed Check ................................... O7-OIB-20 Front Oil Pump ................................................... O7-01B-42Governor Check ................................................ O7-O 1B-22 Front Oil Pump Seal ................................. .......... O7-01B-42Inspection and Verification .................................. 07-01B-8 Governor ........................................................... O7-O1B-50Line Pressure Test m Testing Input Shell and Sun Gear .................................... O7-01B-49

Procedure ...................................................... O7-01B-22 Intermediate Serve ............................................ O7-O 1B-50Engine Vacuum Procedure -- Line Pressure Intermediate Serve Apply Lever ......................... O7-O1B-55

Test ............................................................ O7-01B-23 Main Control Valve Body .................................... O7-01B-36Vacuum Diaphragm Test, Oil-Vehicle .............. O7-O tB-25 Output Shaft Hub and Ring Gear ......................... O7-O1B-55Vacuum Diaphragm Test, On-Vehicle .............. O7-O1B-25 Parking Pawl Linkage ........................................ 07-O18-54Vacuum Pump Procedure -- Line Pressure Reverse Clutch..._ .............................................. 07-01B-51

Test ............................................................ O7-018-24 Torque Converter Checks .................................. O7-O 1B-56Vacuum Supply Test _ Line Pressure One-Way Clutch Check ................................... 07-01B-56

Test ............................................................ 07-01B-24 Staler to Impeller InterferencePinpoint Test ..................................................... 07-0 lB- 15 Check ......................................................... O7-O 1B-56Shilt Linkage Check .......................................... O7-01B-21 Staler to Turbine Interference Check ........ ..... O7-O1B-56

Accelerator Linkage and Operation ................ 07-01B-21 Torque Converter End Play Check .................. 07-01B-57Downshift Linkage ......................................... O7-018-21 ASSEMBLYManual Shift Cable ......................................... O7-018-21 Transmission...: ................................................. 07-018-58

Shift Point Road Test ......................................... 07-01B-21 INSTALLATIONClosed Throttle Downshifts ............................ 07-01B-21 Transmission, E- 150-250-350 ............................ 07-01B-63Forced Downshifts ......................................... 07-018-21 Transmission, F- 150-250-350, 4x2 andManual Oownshifts ......................................... 07-01B-21 4x4 ................................................................ O7-01B-60

Stall Speed Test ................................................ O7-01B-25 CLEANING AND IN SPECTIONSymptom Chart ................................................... 07-01B-8 Backflushing and Cleaning Transmission OilTransmission Oil Condition Check ..................... 07-01B-17 Cooler and Oil Cooler Tubes ........................... 07-01B.67

Oil Level High Before Starting Engine, OK Clutche3 ............................................................ 07-01B-65During Normal Check .................................. 07-01B-17 Direct Clutch .................................................. O7-01B-65

Oil Level High or Low ...................................... 07-01B-17 Forward Clutch .............................................. 07-01B-65Transmission Oil Cooler Flow Test ..................... O7-01B-20 ExtonsionHousing ............................................ 07-01B-65Transmission Oil Leakage Checks ..................... 07-018-17 Governor ........................................................... 07-01B-66

Torque Converter Leakage Chock .................. 07-01B-20 Intermediate Band Serve ................................... O7-01B-66Transmission Oil Level Check ............................ O7-01B-16 Main Control Valve Body .................................... O7-01B-65

Transmission -- Operating Oil Pump ............................................................ O7-01B-66Temperature ............................................... 07-01B-16 Planet Assembly and Center Support ................. O7-01B-66

Transmission Cold ......................................... O7-01B-17 Stator Support ................................................... O7-01B-66Vacuum Regulator Valve (VRV) (7.3L Diesel Torque Converter and Oil Cooler ........................ O7-O1B-67

Engines) ........................................................ O7-01B-22 Transmission ..................................................... 07-01B-64IN-VEHICLE SERVICE Transmission Case .................... _....................... 07-01B-64

Extension Housing ............................................ 07-01B-30 ADJUSTMENTSExtension Housing Bushing and Rear Intermediate Band ............................................. O7-01B-67

Seal ............................................................... O7-01B-29 Park/Neutral Position Switch ............................ 07-01B-68Intermediate Serve ............................................ 07-01B-28 Vacuum Regulator Valve Operational CheckOil Cooler Lines ................................................. O7-01B-27 and Adjustment (7.3L Diesel Engines

Main Control Valve Body ................................. O7-01B-27 Only) .............................................................. 07-01B-68Transmission Oil Drain and Refill ........................ O7-01B-31 SPECIFICATIONSVacuum Diaphragm ............................................ 07-01B-29 Shift Speeds .................................. _................... 07-01B-73

REMOVAL SPECIAL SERVICE TOOLS/EQUIPMENT ................ 07-O 1 B-75Governor ........................................................... O7-O1B-32 PARTS CROSS-REFERENCE .................................. 07-O1B-76Transmission, E- 150-250-350 ........... _................ 07-01 B-32Transmission, F-150-250-350, 4x2 and

4x4 ................................................................ 07-0 IB-31

i

VEHICLE APPLICATION

E- 150-250-350, F- 150-250-350 4x2 and F.250-3504x4 Vehicles with C-6 Automatic Transmission.

Page 518: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-2 Transmission, Automatic, C6 ............ 07_01B_.2' ,._ ....II I Jl

DESCRIPTION

.C6 Transmission-. .... - : . _' _" ' Transmission Identification,- .... ....:_: _'

The C6 transmissionis a three-speed unitcapable of The identificationtag is attached to the intermediateprovidingautomatic upshifts and downshifts through servo lower frontcover bolt.The first lineonthe tagthe three forward gear ratios. The transmission is also shows the transmission model prefix and suffix. A ,_capable of providing manual selection of first and number appearing after the suffix indicates that thesecond gears, internal parts in the transmission have been changedThe converter housing and the fixed splines which after initial production start-up. For example, a .engage the splined outside diameter of the PGDoJFmodel transmission that has been changedlow-reverse Clutch steel plates are both cast integrally internally would read PGD-JF 1. Both transmissions

are basically the same, but some service parts in theinto the case. PGN-JF transmission are slightly different than theOnly one (intermediate) band is used in the C6 PGD-JF 1 transmission. Therefore, It is Importanttransmission.::This along with the forward clutch is that the codes on the transmissibn identificationused to obtain intermediate gear• tag be checked when orderlng_arts or making

inquiries about the transmission:

MONTH BUILD DATE COOE

TRANSMISSION MOOEL _ /

, _/ I PGD.JF I1-_-I

ASSEMBLY PARTNUMBER PREFIX

AND SUFFIX•.' . . D1925-S

Page 519: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-3 Transmission, Automatic, C6 07-01B-3-- I

:RIPTION (Continued) -

......":',LI,:I_'_ ,.",C6_AutomatlcTroansmisslon;iExploded.View_':,_,.... ._:. . ,. .....: . ' "

_avEaseCCuTC_ " __-r '

• • • F. /Br n / . r in/ " rsinAu 1993

Page 520: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-4 Tranamlsllon, Automatic, C6 , 07,01B-4I I Iii I II II

DESCRIPTION (Continued). ' , • . ............ ,... ..... .. ,.: _i_

• Part _ PartNumber Description Item Number Description

1 7902 Torque Converter 28 7A262 Forward Clutch Piston ,._2 7017 ' In >utShaft 2°3 70256 Forward Clutch Piston

..... Front Oil PumpSeat Spring Ring(Part of 7A 103) 30 78070 Forward Clutch Piston Disc

4 7A 10'3 Front Oil Pump Assembly Spring ._Front Oil Pump Body 31 _77127-S Retaining Ring :,°

"_'_! (Part of 7A 103) 32 7B066 Forward Clutch Pressure

:_: Pump Driven Gear Plate _ Front'_ (Part of 7A 103) 33 7E085 Forward C!utch Pressure._., Spring ,-:_"'.' Pump Drive Gear_,+- (Part o17A 103) 34 7B 164 Forwardi.C:tUtch Internal

40 , Front Oi_Pump Bushing " Spline Pla!e_ (Friction)(Part of 7A 103) 35 7B442 Forward' Clutch External

4E Front Pump Support Spline Plate _ (Steel)(Part of 7A 103) 36 7B066 Forward Clutch Pressure

4F 20346-$8 Hex Head Bolt Plate _ Rear_.'.i (Part of 7A 103) 37 377127-S Retaining Ring

5 58619-$2 Bolt 377437-S377444-S6 7A24_8 Front Oil Pomp Seal _ 386841-2-S

•;_ Large 38 70234 Forward Clutch Hub Thrust7 70025 Intermediate Brake Drum Bearing Assembly _ No. 3

-: Seal (2 Req'd) and No. 6 (2 Req'd)8 FA13(3 Oil Pump Gasket 38A 70235 Forward Clutch Hub Thrust9 70029 Intermediate Brake Band Race ,

Strut 38B 70236 Forward Clutch Hub Th.rust10 70034 Intermediate Band Race

. 1l, 70430 Inter.me,dia'te_Ba'nd_/kn/;hor 39 70090 Forward Clutch Hub ThrustStrut Washer _ No. 4

12 7[)014 Thru'_t Washer _No. 1 40 377132.S RetainingR_ng _;i13 70044 Intermediate Brake Drum 4 I 7B067 Forward Ring Gear Hub14 7E056 Direct Clutch Piston Oil Seal 42 70392 Forward Ring Gear

_ Inner 43 .7A166 Planet Carrier Thrust Washer15 7A548 Direct Drive Clutch.Piston O I . No, 5

Seal _ Outer 44 7A398 Forward Planet ,_:-16 7A282 Direct Clutch Piston 45 7D063 Sun Gear Assembly

16A 7B488 Direct Clutch Piston Spring 46 377300-S Front Retainer

( 10 Req'd) 47 70064 nput Shel?!_::17 7A527 Clutch Piston SpringRetainer 48 70066 Input She_Thrust.,,_;:Washer ;,

18 377136-S Oirect Drive Clutch Piston 49 377300-S Rear Ret,'ainer.;:_,_..Spring Retainer Ring 50 377155-S RetainingRing

19 7B442 Direct Clutch ExternaISpline 51 70423 Reverse Planet Carrier "_Plate _ (Steel) Thrust Washer _ No. 7 and

20 7B 164 Direct Clutch Internal Spl{ne No, 8Plate _ (Friction) 52 70006 Reverse Planet

21 7B066 Direct Drive Clutch Pressure 53 387031 -$5 Retaining RingPlate 54 7A153 Ring Gear

22 7C096 Intermediate Brake Drum 55 70164 Output Shaft HubThrust Washer _ No. 2 56 3T7132.S Retaining Ring

23 377126-128-S Retaining Ring 57 70422 Output Shaft Hub Thrust377437 Bearing _ No. 9

377444-S 58 7B067 Reverse Clutch Hub24 7D019 Forward Clutch Cylinder 60 7A089 Overrunning Crutch

Seal (2 Req'd)25 7A360 Forward Clutch Cylinder 63 385044-S Retaining Ring

Assembly 64 7B066 Reverse Clutch Pressure26 7A548 Forward CrutchPiston Oil Plate

,_ 'Seal _ Outer 65 7B442 Reverse Clutch External27 7A548 Forward Clutch Piston Oil Spline Plate _ (Steel)

Seal _ Inner 66 7B 164 Reverse Clutch InternalSpline Plate _ (Friction)

(Continued)

1994 Econoline/F.150. F-250. F-350/Bronco/F-Super D_y Powertr_in_rlvetrainAun 1_93 ,

Page 521: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-5 Transmission, Automatic, C6 07-01B-5III I I I II

DESCRIPTION (Continued) . _. ,,

Part PartItem Number ' Description , Item ....... Number Description

67 . 7E085 ., Reverse Clutch Pressure 102 7A233 Output Shaft Park Gear

Spring 03 7B388 -, ,Output Shaft Thrust Washer68 70403 Reverse Clutch Piston Outer -- No, I0 ._ '

Seal t04 700,,5 . Case69. ,70404 . Reverse Clutch.Piston Inner.. 105 7034 , .Vent

Seat t06 70273 .... • "Oil Tube Connector70 -- Overrunning Clutch Race -- (2,Required)

Inner (Part o( TD t64) 107 ' 3'3798,S8 _ Nut --5/,16

71 70406 ,' Reverse Clutch Retaine!" and 108. 34806oS7 ., , " HexLock'Wa,sherSpring Assembly° , t09 " 1.7A394 Oownshift Control Outer

72 70402,,, ",_:.;_ .Rever, se Clutch'Riston -_ ", '_ '_ " Lever

73" 70167 : ' ......i,'ii, _OverrunningClutchto_Case.:", '""' " 110 55651.$2' Screw and Washer°. Bolt (5,Req'd) Assembly

74 57633-$2 Bolt. (4 Required) I I I 7A247 Park/Neutral Position ,.75 Transmission Model ' Switch

Identification Tag t 12 ':386078-S :, _.,!Throttle Control Outer Lever(Hot Serviced) ' ,, Seal .

"76 7D027 Intermediate Band Servo 1,13 ' 7A256,", ,. ,,, ManualControlLever,Cover 114. 7B498 ManualControl Lever Oil

,77 70024 Intermediate Band Servo Seal

Cover Paston Seal -- Large I i5 6572 ,;Parking Plate Shaft Plug.78 70026 Intermediate Band Servo

Cover Gasket -116 70418 ' -Parking Plate Shaft"

79 70021 ntermediateBandServo- 117 , 70414 ...... , -, " _P.arking Rod Support Plate-Piston and Rod Assembly .... 118 704 t 7 ,Parking Plate Torsion Spring

'80 70028' '., .' ,, Intermediate Band.Servo I.I.9 7A26,1 . ." Manual,ValveDeten1LeverPiston Spring :, _.,/.: Spt:in,g,,,', ,j _.,: •_..,:-,:-:_'/_::;: 'ix, ,-

81 7060 Output Shaft 120 5650 t.S2' He× FIg Bolt, t/4-20 x .50

82 7086 Extension Housing Gasket. 121. 7A115 Manual Valve Oetent Lever

83 7G496 Vacuum Tube Retainer • -- Inner (Serviced in Kits(2 Req'd _ 4x2) Only)

83A 7G496 Vacuum Tube Retainer 122 380525-S Hex Lock Nut. 9/ 16-18(2 Req'd _ 4x4) 123 7026 I Downshfft Detent Lever

84 380209.S B01t. 4 Req'd Inner

85 7A039 • Extension Housing -- (4x2) 124 7041 I ParkingPawlActuating Rod(Serviced in Kits Only)

85A 7A039 Extension Housing _ (4x4) 124A 87650-S Pipe Plug -- l/8-27 Dryseal86 7A034 Extension Housing Bushing Tapered Thread (Used in87 7052 . • Exten s on Ho_si.ng,Oi[:.Seal :. " Case for Measuring Pump88 380207-$2 ' Bolt"(2 ReCl_d""--.:"4x2 Only)'", Pressure)

88A 58642-$2 : :_` B01t'(2_Req'cl_',4_'i:4'0nly) ' _' '": ...... 1248 87650-S Pipe Plug -- 1/8-27 Dryseal' • " _ (Used in Case for Measuring

89 7C063 Governor Body Assembly Throttle Valve Pressure)

89A 34805-$8 Bolt. 4 Req'd 125 7A377 Throttle Vatve Control,90 70220 Governor Body Oil Collector Diaphragm Assembly

Body 126 7A380 Throttle Control Valve Rod91 7001 I Governor Housing Seal Ring

(3 Req'd _ 2 Teflon. 127 7F006 Vacuum Diaphragm Clip1 Cast Iron) 128 7F013 Vacuum Diaphragm Heat

92 387035-$5 Retaining Ring Shield

93 7C232 OilOistributorSleeve 129 56119-S Hex FIg Head Bolt. 5/16-16" ' x .82 _ (7F013.77006 and94 20386-$8 Bolt. 4 Req'd 7A377 to 7005)

95 70000 Oil Distributor Tube _ Inlet 129A 7A 1OO Main Controt Assembly96 70000 : Oil Distributor Tube _ Outlet 130 70075 Inner Downshift Lever Stop97 379058oS Screw and Washer (Part of 7A 100)

Assembly t30A 7326 Gear Selector Valve Rod

98 704 t 9 Park Rod Guide Plate t 3 t 7A092 Upper Control Valve Body(Serviced in Kits Only) (Part of 7AI00] ,.._

99 7D070 Parking Pawl Return Spring t 32 7C056 Main Control Valve Body100 7A44 t Parking Brake Pawl Reinforcement Plate (Part of

101 70071 Parking Pawl Shaft TA 100)

(Continued) (Continued)

Page 522: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-6 Transmiselon,Automatlc, C6 .... 07-01B-6- I Ill I I I I

(Cotin d)• DESCRIPTION n ue :....

m l -Part ...... " " ....... , Part IIre Number Description Item Number JDescription ;133 70259 Main Control Valve Body 144 7A 178 Adjusting Screw ._.

Separator Plate (Reverse Band) 'JReinforcement (Part of 145 375185-S 100 Nut

::.. .. 7A I00)_. '" " 146 7330 Intermediate Servo Band;; 134 7E387: Main Control Pump Inlet Lever

_r_ Screen 147 7E206 Intermediate Band Servo _"135 7A008; Valve Body Separating Plate ' Lever Shaft Retainer

(Part of 7A 100) 148 7D433 ! Intermediate Band Adjusting!, 136 70 tO(_, Valve Body Separating Plate Lever Shaft

'_ Gasket._ 149 378259 Cup Plug "_137 7A 10_1' Lower Control Valve Body,_: 150 70094 Throttle, PPJ_ssure Booster

!. (Part of 7A 100) Valve Plat_;(Not Serviced:_;:! 138 7E062, Oil Pan Screen Gasket Separatel_;)_: ',

139 7A098 OilScreen 150A i 70227 Throttle Pressure Valve139A 7A 191 Oil Pan Gasket _ ,I Secondary Spacer

140 7A 194 Transmission Oil Pan -- 15 t 70058 Shift Valve Plate

_ (Shallow -- 4x2) (Not Serviced Separately),,_'_, -- (Deep -- 4x4) i_; 152 7A 102 Lower Main Control Valve

141 378782-S Bolt Body Suction Tube ,142 7008(_I Primary Throttle Valve 153 7H 183 Extension Housing Plug

_' 143 87650":S Converter Drain Plug. , (Used to Plug Speedometer' t 18-27, Oryseal Tapered Gear Hole)

Thread 154 57621-$2 Screw and WasherAssembly, 1/4-20 x .62

,,_ (Continued)

:. _.;:_.,°.

1994 Econoline I F- 150. F-250. F-350/Bronco I F.Super Duty Power'train/ Drivetrein Aug 1993

Page 523: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-7 Transmlsslon, Automatic, C6 O7-O I B.7.BB

1994 Econoline/F-150, F.250, F.350/Bronco/F.Supe_ Duty Powertrain/Orivetrain Aug 1993

Page 524: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-8 Transmlnlon; Automatic, C6 07-01B-8I II I II I II -

. , : ,.

•.: DIAGNOSIS AND TESTING "t,. "_ . ' ,

-Troubleshootingtheautomatic'transmissionis: ,- ' - ' e.. Noise/Vibration .......

,-simplified byusing proven methodsof diagnosis:One • , ; ' ' NOTE: If noise/vibration check for,, of the most important things to remember is that there dependencies.'. is a definite procedure to follow. Do not try to short cut ....

or take it for granted that someone else has done the -- RPM dependent. ,_

;!,,critical check s or adjustments, m Vehicle Speed dependent.

;'_The following procedures,arerecommendedfor "._ -- Shift dependent.

,_ checking and _or verifying that the various -- Gear dependent. _ ,._'_',_ components a_e adjusted and operating properly. If an"Automatic Trafismission Tester is used, Rotunda m Range dependent.

;:. model 014-0G737 or equivalent, follow the -- Temperature dependent.i. 'manufacturer)s instructions.

_,, 3. Vehicle at normal operating temperature.,_,Prel mlnaryD_lagnostics

'. ,/:, 4. Check transmission oil level a'i_l.Cohdition. _,i.!'The following items must be checked.before ..,

_': proceeding: " 5. Visually inspect the vehicle f0_te following" ::.,, items: '_i ,. 1. Know and understand the customer's concern. a. Vehicle modifications.

' 2. Validate customer's concern (when does it'. exist?). :_i, b. Electronic add-on items.

a. Ups;hilt c. Leaks." ._-'_ d. Proper linkage adjustments•

b. Downshift

c. CoaSting 6, Check Technical Service Bulletins and Oasis forconcern information•

,,. d. Engagement

_'_Inspection and Verification 2. Transmission oil level and condition check. Check

' 1. Determine concern re_ative'toWehicle_dsage, for contamination or burnt odor. Check for leaks.

• Hot or cold vehicle operating temperature 3. Check shift linkage, downshift linkage and .--_vacuum lines for proper adjustment and .;• Hot or cold ambient temperatures installation.

• Type of terrain 4. Verify park / neutral position switch is adjusted

.......... _e Vehicle loaded/unloaded .... properly in Neutral. . ..............

• City or.highway driving 5. Road test vehicle to confirm customer concern.

%Symptom Chart ._,_:. .....

The symptom charts in this section can be used as an __:_aid when diagnosing the C6 automatic transmission. " '

SYMPTOM CHART _ AUTOMATIC TRANSMISSION

CONDITION POSSIBLE SOURCE ACTION

Slow initial engagement in either • lmpropero_level. • Perform oil level check,forward or reverse range. • Damaged or improperty adjusted • Service or adjust linkage from ._

linkage (shift cable), steering columnto transmission.• Contaminated oil. !• Perform oil condition check. _

• Improper clutch and band l• Perform line pressure test.application, or low main controlpressure.

1994 Econoline/F. 150, F-250. F-350/Bronco; F-Super Duty Poweftrain/Orivetra!n Aug 1993

Page 525: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-0 IB-9 Transmission, AutomaUc, C6 • 07-01B-9i

DIAGNOSISAND TESTING(Continued) •

' ;"" :-"._;i_; '.:'_ ': . i'/::.. _ .. :': SYMP'TOMCH'ART:/--_AUTOMATICTRANSMISSION(CO_ttlnusd): :.,........ 'dr q: '

CONDITION" " POSSIBLE SOURCE ACTION '

Rough'•initial engagement in either • Improper oil level. • Perform oillevel check.• , ,forward:err•verse. • _,. • ,Highengineidle• , '_ ' •- Adjust idle to specifications. Refer

to the Power/rain• . _r,'Control./Ernissi,onsDiagn_i s ..... .. !: _;,..=,;,;:i_

Manual. _..... , ., . '- • •Check vacuumregulator•valve.for , ' -. •,:_._'Adjustor,repace vacuum regulator

: _7.3Ldiesel.C6app ca/one. , ,valve. -• Looseness in thedriveshaft. . ,. ,' e":Sef_vce,asrequired..

U.-joints or engine mounts•• Improper.clutch or band ' "' • :Perf0rmlinePressuretest•

,...:",- _..... application,lot.oil control pressure., : , : : ,.

• ,.-,.....,._. •,:"Sticking or dirty, main control valve :- e Clean,.serviceorreplacemainbody. control valve body. ' ....

Harsh engagements --:w, arm,engine_,,,,_ .e.:_lmprop'er-_oil;level:."' ' • . Perform oil level check... • Engine curb idle too high. • Check engine curb idle. Refer to

the Powertrain Control / Emission s' Oiagnosis Manual. _

. • Check vacuum regulator valve for , ,e iAdjustorreplace;vacuumregulator7.3L diesel. C6 applications .... valve..

• e, Main control valve body bolts-- ." .- • ."Tighten to specification.• _loose/too tight. , - •.,

• Main control valve body . • ,.Determine source ofdirty/sticking valves• contamination. Service as.;.

• required.

No/delayed forward engagement • Improper oil level. , ' • .e ;Perform oil level check.(reverse OK). ' , •_ Transmission shift cable•and " • ,Check and:adlust or service as

,. bracket --.'misadlusted / damaged required.,, ',, _ ' ' ,, . 0,_ Low,main control pressure, 0'., Perform nepressure'test, note. '

:, (leakage)'. Front clutch support results." ' .seal rings leaking (No. 3. No. 4). " ". ' : " ..... ' .... '• Forward clutch cylinder assembly • Perform air pressure test.

burnt/damaged/leaking. Checkball in piston/leaking piston seals.

• Main control valve body bolts-- • Tighten to specification•loose / too tighL

• blain control valve body • Determine source ofdirty/sticking valves. • contamination. Service as

required.• Transmission main control screen • Replace transmission main control

plugged, screen.• Front pump support and gears • Visually inspect front pump support

damaged/,leaking, and gears• Replace if necessary.No/delayed reverse engagement, .,,: ......•,,, lmproperLoihlevel:-, • Perform oil level check.'(forward OK). ,, • .Transmissi0n,'shiftcableand • Check and adjust or service as

bracket,misadjusted / damaged, required.• Low main control pressure in • Perform line pressure lest.

reverse. Reverse clutch drum OK.• Reverse clutch drum assembly • Perform air pressure test.

' " burnt / worn / leaking. Leakingcheck ball in high/reverse clutchpiston/leaking piston seals.

• Main control valve body bolts • Tighten to specification.loose / too tight.

• • Main control valve' body • Determine source ofdirty / sticking valves, contamination. Service as

required.• Transmission main control screen • Replace transmission main control

plugged, screen.• Front pump support and gears • Visually inspect front pump support

damaged, and gears• Replace if necessary.

No/delay•dr•vats•engagement • Improper oil level. • Perform oil level check.end/ornoenginebrakinginmanual: • Clutch piston seals.leaking. • Check and replace clutch pistonlow. seal•

• Transmission shift cable and • Check and adjust or serviceasbracket misadjusted/damaged, required.

t Canbepurchasedas • separate item,L ' " " " " " ' '

Page 526: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B- 10 Trans miss Ion, Automatic, C6 07-01B- 10

r" DIAGNOSISAND TESTING (Contln'ued) " ' ''_ __

...... .,. ._ .,':"SYMPTOMCHART .... _AUTOMATICTRANSMISSION: Cbntlnu_d) _..... " ' ' " _"_ " ':_ "

CONDITION POSSIBLESOURCE. ACTION

No engine braking inmanual second • Intermediate band out of • Adjust intermediate band. -_-gear. adjustment. _::

• Improper band or clutch • Perform line pressure test.• ./, application, or oil pressure control

system,:_ • Intermediate servoleaking. • Perform air pressure test of ",'_,,

intermediate servo for leakage. !P,'':_'.. Service as required.

• Polished or glazed band or drum. • Service or replace as required,• Transmission shift cable and • Check and adjust or service as

,_' bracket misadjusted / damaged, required. ,_.

Forward engagement • Improper oil level• • Perform oilleve'i_check.slips/shudders/chatters.. • Transmission shift cable and_ • Check.and.adj_"s_,or service.as. _:

bracket misadjusted/damaged, required. ' _"• Low main control pressure• • Perform line pressure test.• Main control valve body bolts _ • Tighten to specification.

loose/too'tight•,_, • Main control valve body • Determine sourceof.'_!; dirty/sticking valves, contamination. Service as,.;_ required._T' • Front clutch piston ball check not • Replace forward clutch piston: .• .._;, seating / leaking. Service transmission as required.

• Front clutch piston sealscut/worn., • Replace seals and service_ one-way clutch as required..

• Low one.way clutch damaged• • Determine cause of condition., Service as required.

Reverse engagement • Improper oil level. • Perform oil level check.shudderslchatterslslips. • Low maincontrolpressure in • Perform line pressure test• _'_'

reverse.

, -,_,.__,-,,:_-, ,,e:,: Low_reverseclutchlleaking • Air pressure test; visually inspectpressure. ' seal rings and piston bore.

• Clutchpislonsealscut/worn. • Determine cause of condition.Service as required. _!_

• Looseness in thedrivesheft, • Service as required•U-joints or engine mounts.

No drive, sl!ps or chatters in first gear • Low one.way clutch damaged. • Service or replace one-way clutch.•in O_All-other gears normal: . ..............

No drive, slips or chatters in second • Intermediate band outof. • Adjust intermediate band. ".gear. adjustment.

• Improper band or clutch • Perform line pressure test.

application, or control pressure. . ,_,..... ,• Damaged or worn intermediate • Performa_rpressuretest. '_

servo piston seals and/or internal

Ie aks, -;_L_,".• Dirty or sticking main control valve • Clean. service orTeplace main

body valves, control valve,body• ,,• Polished. glazed intermediate • Replace or service as required.

band or drum.

Starts up in2ndor3rd. • Improper bandend/orclutch • Perform line pressure test.application, or oil pressure controlsystem.

• Damaged or worn governor. • Perform governor check. ReplaceSticking governor primary valve, or service governor, o.... _

• Main control valve body bolts • T_ghten to specification. :;_loose•

• Dirty orsticking main control valve • Clean. service or replace mainbody valves, control valve body.

Q Cross leaks between main•control • Service or replace main controlvalve body and case mating valve body and/or case assurface, required.

1994Econoline/ F"150,F'250. F-350/Bronco /F'Super DutyPowertrain/ DrivetrainAu 1993

Page 527: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B- 11 Transmission, Automatic, C6 07-018-11" I II

DIAGNOSISANDTESTING(Contlnued), ..... .... . " . • _.

:,,....,_,SyMP,TOM,CHAR T _..;.AUTOMATIC TRANSMISSION, ,CohtlnU,e_)., _..;,. ,_:.. . . -

, .CONOITION POSSIBLE SOURCE , • ACTION

Shif t points incorrect. • • Improper oil level. • Perform oil level check:: . , • Vacuum line damaged,clogged or . • Perform vacuum, supply test.

leaking. Check ;co,nnect vacuum lines to "• regulator.valve,on 7;3L diesel.

• , .e Improper_.operationofexhaust.gas,.., ' ,• Service,orreplaceas.required.• recirculation system..', '

: • Improperclutch.orband - •, Perform,shitrtest,,andlinepressureapplication, or oil pressurecontrol test•

•system.• Damaged or worn governor. ., , : or replace governor.

, • Throttle.controlvalve rod ......... i ...... , •' .Replace ............. .....,., .:..,_,.,..;.. ' ;,;" " _,.:'-mis'sing/.incorrect length or .." .... ." ,_ ..'

. ......... ;',i _"throttle'valve control diaphragm. "" " ..... : ...... " .... assembly bent or leaks•

• Dirty or sticking main control valve • Clean,, service or replace mainbody valves, control valve body.

• Vacuum regulator valve •. Check adjustment and function.misadlusted or damaged (7.3L Adjust or replace•Refer tod_esel). " " adjustment procedure in this

,' section.

,.Allupshittsharsh/deiayedorno. • " :,'• 'Improper oil level. ,........ '_:.e...Perform,oillevel:check• "upshifts. • Transmission shift cable and ; .•. •Check-and adjust or service as

bracket -- misadjusted/damaged. required.• ,• Governor seconda_y valve • ,Perform,governor test. Service as

sticking. , required.• •- Main control pressure too high. " _ .:, •_.Perform.linepressuretest.,Service

• as required.'' _ • Main.controlvalvebody:bolts:-- .,: •: Tighten to spec fcahon.

• • Ioose/too tight. •• • , Main control valve body ,,•..,Determine:sour.ce-o'f,- .... . :., ', ..., ,,

:dirty / sticking valves, contamination. Service a srequired

• Vacuum leak to throttle valve • Check vacuum lines to d_aphragmcontrol diaphragm. unit. Service as necessary.

Perform vacuum supply test•• Vacuum regulator valve • Check adjustment and function.

misadjusted or damaged Adjusi or replace• Refer to vacuum(7.3L diesel), regulator valve adjustment

procedure in this section•• Downshiftcableordownshift • Replace/repairoradjustas

control outer lever damaged/stuck required.open.

Mushy/early all ups hi.ftsJ:pileup_ :-,,;_ ,;_. ,,:,e!..,Eow_main,control;pt'essure. • . • Perform line pressure test• Noteupshifts, results.

.,.. • Main corntrol valve-body bolts -- • Tighten to specification.• loose / too tight•

• Main control valve body valve or • Determine source ofthrottle control valve sticking, contamination. Service as

,,_ .. required.Governor primary valve sticking. • Perform governor test. Repair as

required.• Throttle control valve rod too • Install correct throttle control valve

short, rod.

• Vacuum regulator valve • Check adjustment.and function..misadjusted or damaged Adjust or replace. Refer to vacuum,(7.3L diesel), regulator valve adjustment

procedure in this section.

' o . • o . . , •

Page 528: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B- 12 Transmission,' Automatic, C6 07-01 B- 12. i i i , =

(c d).......... 'DIAGNOSIS:AND TESTING ontinue • .... '

.:,. . . ' . ._;'.SYMPT_OMCHART.-_.-.AUTOMATIC TRANSMISSlON'(Con'tlnued)/:-, ...... " ".... '" :/_ ,.::""."

CONDITION POSSIBLE SOURCE ACTION

No t-2upshift. • Improperoillevel. • Performoillevelcheck.,. • Vacuum regulator valve • Check vacuum regulator valve for -"_'_ misadjusted or damaged. 7.3L diesel, refer to appropriate_:, _ i_ (7.3Ldiesel). section inthis manual•,_ • Transmission shift cable and • Check and adjustor service as

bracket -- misadjustedldamaged, required. • "_,_,;_, • Governor primary valve sticking. • Perform governor test• Service as :";;"_:" required._ • Intermediate band outof • Adjust intermediate band._-: adjustment.._. • Throttle valve control diaphragm • Check throttle gal,_econtrol_,- bent, sticking, leaks• diaphragm• Servlice as necessary:.:, . • Main control valve body,bolts_ -. • '. Tighten to speci'f_ation. "

loose / too tight. ,":'• Main control valve body • Determine source of

dirty / sticking valves• contamination• Service asrequired• : ...

• Intermediate band burnt and/or • Perform air pressure test._;! servo assembly leaking.

Rough/harsl_i/delayed 1-2upshift. • Improper oil level. • Perform oil level check.,_!,; . • Poor engine performance. • Tune engine._; • Intermediate band out of • Adjust intermediate band._ adjustment.

• Main control pressure too high. • Perform line pressure test. Note.- results•_, • Governor primary valve sticking. • Perform governor test. Service as._ required.

• Engine vacuum leak. Vacuum • Check engine vacuum lines. _:_:_,:.. line(s) not connected/damaged. Service as necessary. Check-throttle valve control diaphragm.Service as necessary. Performvacuum supply and throttle valvecontrol diaphragm tests. "" -;

• Main control valve body bolts • Tighten to specifications.loose/too tight.

• Main control valve body • Determine source ofdirty/sticking valves, contamination. Service as _ .

.............. required. '_ ' '• Vacuum regulator valve • Adiusforreplacevacuumregula.tor

misadiusted or damaged valve. Refer to vacuum regulator(7.3L diesel)• valve adjustment procedure in this

section•

Mushy/early/soft/slipping 1-2 • Improper oil level. • Perform oil level'_heckLupshift. • Incorrect engine performance. • Tune adjust engin_'idle as

required• %"-,• Intermediate band out of • Adjust intermediate band.

adjustment. :;. _-

• Low main control pressure. • Perform line pressure test..Note... ' results.

• Main control valveb0dybolts_ • Tighten to specification. .,loose / too tight.

• Main control valve body • Determine source ofdirty/sticking valves, contamination. Service as

required. . .,_• Damaged intermediate servo or • Perform air pressure test. Service ,',_

band. as required.• Polished, glazed intermediate • Service or replace as required.

band or drum.

• Vacuumregulatorvalve • Adjust or replace vacuum regulator :_misadjusted or damaged valve. Refer to vacuum regulator(7.3L diesel), valve adjustmentprocedure inthis

section.

" 1994Econoline/F. t50. F.250. F.350/Bronco/F.SuperOutyPowertrain/Odvetr,,inAu 1993

Page 529: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B- 13 Trans mission, Automatic, C6 07-01B- 13I

: '.DIAGNOSIS ANDITEST,ING (Continued)_- " "

" .... :._.:_-.s'_" ".:,, ...... :: ' • MPTOM CHAR'F,,_ AUTOMATIC'TRANSMISSION COntlhued] ::.... ' '-"

.CONDITION ' POSSIBLESOURCE ACTION

No 2-3upshift. • Low oil level. • Perform oil level check.

• For7.3LdieseI. C6 application -- ' • .. Adjust or replace vacuum regulator -vacuum,regulator valve , : : valve: Refer to vacuum regulatormisadjusted or damaged. .valve,,adiustmenl.procedure in this "

: section•

- , ., • Low:main.controlpr, essureto •: Perform line pressure test,. Notedirect clutch, results.

• Maincontrolvalvebodyboltsw • Tighten to specification., Ioose/tootight.

• , Main control valve body ,- . •' Determine source of, dirtyj_s.ticking.valves. . contamination. Service as

..... • required.•' .... ' - . e _Oirect.,cluichpiatesor'assembly , • Oetermine cause of condition.

" , .... burnt/worn: Clutch piston seals Service as required,damaged.

Harsh/delayed 2-3upshift. • Incorrect engine performance. • Check engine tune-up.• Engine vacuum leak. Vacuum • Check engine vacuum lines., -line(s) not connected/damaged. • , .Service.as necessary. Check

, .... ,: _throttle valve_control diaphragm... ," ,Ser,vice as necessary, Perform

• , ,=,vacuum:supply and throttle valve. . . controld=aphragmtests. Check

.vacuum regulator valve tot 7.3Ldiesel.

.,. • Damaged or worn.intermediate , ,, .!.,• _Air,pressuretest.the, intermediate•. . o_ ;. ,.servo and highclutch piston seats.. ,, 'servo. Applyand release the high

: clutch piston check ball. Serviceas required.

• • • Main, control valve body bolts .... , - • • Tighten to specification."loose/too tight.

• -Throttle valve.control diaphragm or' • Check throttle valve controlthrottle control valve rod bent. diaphragm and throttle controlsticking, leaks, valve rod, Replace as necessary.

• Vacuum regulator valve , • Check adjustment and function.misadiusted or damaged Adiust or replace. Refer to vacuum(7.3L diesel), regutator valve adjustment

" procedure in this section.

Soft/early/mushy2-3upshift. • Main control valve body bolts-- • Tighten to specification.loose/too tight.

• Main control valve body " • Determine source ofdirty/sticking valves, contamination, Service as

required.",,_,_ ...: :;._ .,. •._Throttle valve control diaphragm or,. • Check throttle valve control

,_...:_ --.-.,,_,,,J ,,,..... ,..throttle:control valve rod bent. diaphragm and throttle control "sticking, leak, s.; valve rod. Replace as necessary.

• Vacuum regulator valve • Check adjustment and function.misadjusted or damaged Adjust or replace. Refer to vacuum(7.3L diesel), regulator valve adjustment

procedure in this section.

Erratic shifts. • Poor engine performance. • Check engine tune-up.• Main control valve body bolts • Tighten to specification.

loose / too tight.• Main control valve body • Perform line pressure test. Note

dirty/sticking valves: "_ results• Determinesource ofcontamination. Service as-required•

• Governor primary valve sticking. • Perform governor test. Service asrequired.

• Governor seal rings damaged. • Service as required.

1994 Econoline / F- 150, F-250. F-350/Bronco / F-Super Outy Powertrain / Orivetrain Aug 1993

Page 530: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-14 Transmission,Automatic,C6 07-018-14

. DIAGNOSISAND TESTING(Contlnued) •

.,.. SYMPTOMCHART,N AUTOMATIC ,TRANSMISSION Contlnued)_/_ ' : • _,_ _-_. : ,_-.

CONOITION POSSIBLESOURCE ACTION

Shifts 1.3inD. • Intermediate band out of • Adjust intermediate band.adjustment, ._

_ • Damaged intermediates•rye " • Perform air pressure test. Service _ _?"_; . and / or internal leaks, front servo and/ or internal leaks.

• Improper band or clutch • Perform line pressure test.application, or oil pressure controlsystem. _!,_

• Polished, glazed intermediate • Service orreplace intermediate":" band Ordrum. band ordrum.' • Dirty or sticking valve body valves. • Clean, service or replace valve ',"_:: body•

Engine over-sp'eeds on 2-S shift. • Intermediate band or direct clutch • .Serviceorrepa_'_.,_• , worn or glazed. ._

• Improper band or clutch • Perform line pressure test.application, oroil pressure control -'system•

• lntermediateservopistonseal • Replace seals. Checkforleak_._. _-worn/cut I leaking.

._t, • Dirty or sticking main control valve • Clean, service or replace main

..... body valves, control valve body.-iii_i, • Vacuum regulator valve, • Check vacuum regulator valve.::_,_ misadjusted or damaged (C6 with Refer to vacuum regulator valve_:: 7.3L diesel), adjustment procedure in lhis

section.

Rough / shudder 3- t shift at closed • Incorrect engine idle or • Tune, and adiust engine idle. Refer

throttle inD.... performance, to the Powertrain Control/EngineEmissions D,agnosis Manual•

_' • Improper clutch or band • Perform line pressure test.application or oil pressure control ,, _"_

, , system.• Improper governor operation. • Perform governor test. Service as

required. ,_._• Vacuum regulator valve • Check vacuum regutator valve.

misadlusted or damaged (C6 with Refer to vacuum regulator valve7.3L diesel), adiustment procedure in this

section.• Dirty or sticking main control valve • Clean, service or replace main --

• body valves: control valve body.

No forceddownshifts. • Downshift control lever or cable • Service or adjust cable orleveri"out of adjustment.

• Damaged internalkickdown • Service internalkickdownlinkage.

linkage. . _;.._..... :.... .'• Improper clutch or band • Perform line pr.e_:sur.?.t,e.st.

application, or oil pressure controlsystem. ,,_'A_,,,. .......

• Dirty or sticking governor primary • Perform governor test. Service orvalve, replace governor. '"

• Dirtyor sticking main control valve • Clean, service, or replace mainbody valves. •. controlvalvebody_"'

Engineover-speedson3-2downshift. • Intermediateband outof ' ' • Adjustintermediateband,adjustment.

• Improperband orclutch • Performlinepressuretest.Serviceapplication, or oil pressure control clutch, :,,system• "_;

• Damaged or worn intermediate • Air pressure test check the _"serve piston, intermediate serve. Service serve.

• Polished, glazed band or drum. • Service or replace as required.• Dirty or sticking main control valve • Clean, service, or replace main ,_

body valves, control valve body,

Selector lever efforts high. • Transmission shift cable and • Check and adjust or service asbracket damaged / misadjusted, required.

• Inner control manual levet nut • Tighten nut to specification .........loose.

• Manual lever shaft retaining pin. e. Adjust linkage and install new idamaged, manual levershaftretainingpin.

2/ Can be purchased as a |sparer• item.

1994 Econoline/F-150,F.250, F.3501BroncolF.Super DutyPowertrain/OrivetrainAug 1993

Page 531: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B- 15 Transmission, Automatic, C6 07-01B- 15I I I

DIAGNOSIS " (C' AND TESTING ontinued):,

' _:":i':" '" :: __:" ....... _ " ": '_' " :'"SYMPTOMCHART_'AUTOMATICTRANSMISSION(cbntlhu_ed):'_s_":• . , ' '" " 'CONDITION POSSIBLE SOURCE ACTION

Transmission overheats. • Improper oil level. • Perform oil level check.• Incorrect engine idle, or • ,Tuneor.adiustengineidle. Referto

.performance• . the Powertrain'Control / Engine.-Emissions Diagnosis Manual. 3 ',

•e Improper clutch or band .. • Perform line pressure test•application; or oil pressure•controlsystem.

• Restriction in transmission oil, . . •, Perform cooler flow test.cooler or oil cooler tubes.

• .• ,,..Seized converter one-way,clutch ..... '. ,' •: Replaceone-way clutch.• Dir, ty or sticking main control ya!ve,,.:, _,,,_,•, ...Clean ser.viceor.replace main

• ":- ' '_ , :_ : "bodyvalves:. " - ': _........ _,control.valve body.,'- -..

' -. ", Transmission, leaks. .., . , , •"Casevent:.. ' • Check'the vent for free breathing.•- Repair as required•

' • Leakage at gasket, 'seals, etc. • Remove all traces of lube onexposed surfaces of transmission.

: : Operate transmission_'at normal. temperatures and perform oil

' '_ . ,, .leakage check. Service as. required.

Poor.vehicle acceleration. _,"7 .... •. Poor engine performance. '-'. 'e _.,,:Checkengine tun•up: Refer to the• .Powertrain Control/Engine "

, Emissions Diagnosis Manual. 3, • . Torque converter one,way clutch ,,'. • Perform torque converter checks.

, shpping. " " :

Transmission noisy--valve •'.lmproperoillevel. ,' • Perform oil level check.resonance• . .,- , e' Linkage out of adjustment. • . •- Service or adiusthnkaga.

. • Improper band or clutch •.', Perform line pressure test.NOTE: Gauges'may eggtavate any ,:, -' •a!splication, or oil pressure control '" ''hydraulic resorlance: Remove gauge system. ' ,' ' " :/and check for resonance level. • Oil cooler fubes grounding. , • Relocate oil cooler tubes.

• . • Dirty or sticking main control valve • Clean. service or replace main., body valves, control valve body.

• Internal leakage or pump • Service asrequired_cavitation.

Vehicle will not start. • Misadjustedpark/neutralposition • Adjust park/neutral positionswitch, switch.

NOTE: For 7,3L diesel engines • M,sadjusted ignition switch. • Adiust ignition switch.equipped with C6 transmission, refer • Worn or damaged ignition switch. • Replace ignition switch•to the appropriate portion of Gr0up 03 • Wornordamagedpark/neutral • Replacepark/neutralpositionfor additional information, position switch, switch.

Pinpoint Test

TRANSMISSION NOISY -- OTHER THAN VALVE RESONANCE _ TEST A

TEST STEP RESULT lb" ACTION TO TAKE

A1 I VERIFY NOISEJ

• Check for gear noise to verity if within normal range, . Yes ... _ Normal condition.

• Isnoisewithlnnormalrange?... No • GO.toA2.

A2 I TRANSMISSION SHIFT CABLE AND BRACKET CHECKq

• Check transmission shift cable and bracket for Yes • GO teA3.

proper adjustment, wear or damage, No • SERVICE, REPLACE• Are transmission shift cable end bracket OK? and/or AOJUST

transmission shift cableand bracket as required,

- 3 Can be purchased as a separate item.1994 Econoline / F- 150, F-250, F-350 / Bronco / F-Sugar Duty Powertrain / Otivetrain Aug 1993

Page 532: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B- 16 Transmlulon, Automatic, C6 07-01 B- 16 ....L I II IIll ' '

TESTING (Continued)• DIAGNOSIS-AND "" - .'

j,. :; TRANSMISSION NOISY. _.- OTHER;THAN VALVE RESONANCE',-:- TESTA (Cot_tinued] _'"""" " _.:.:,i

" 'TEST STEP..• RESULT •! ACTION TO TAKE ""

A3 IOIL CHECK• Cl_eck the oil for proper level• Yes • GO to A4. ("_

• I_iollatpropertevel? No • ADD specified oil to bring "_L" -- , " ;., levelbetween ADO and4. FULL marks with vehicle

at operating temperature. _'-__,- GO to A4.

A4 I ST._[" TESTl _!erform the StalI Test as described under StalI Test Yes • GOIoA5,

irl_the Diagnosis and Testing portion of this section.• D_esnolaeatop? No • EXAMINE torque °;

• conv_:ier and front pump:" assembly. SERVICE or

REPI_"_CEas required•Also CHECK for loosetorque converter to,:...

,. flywheel bolts or nuts.

ASI NO,CHECK• Run transm,ss=on in all gears and check for noise• Yes • SERVICE both planet

• Is!_nolse still present? assemblies as required'._._ No • Problem not in/:, transmission. REFER to::_ Section 00-04.

,. Transmlsslon Oil Level Check Transmission _ Operating Temperature "

_: CAUTION! Your vehlcle_shbuld_h0tt_'e:di'l_ten if the NOTE: If the vehicle has been operated for anoll level is below the bottom hole (F-Series) or extended period at high speeds, in city traffic during :COLD area (E-Series) on the oil level Indicator hot weather, or pulling a trailer, the vehicle should be(7A020) and outside temperatures are above turned off for about 30 minutes to allow the oil to cool _10"C (50°F). before checking. ."

Ford automatic transmissions use Motorcraft 1. -With vehicle on a level surface, start the engine• MERE;ON _Multi,Purpose-Automatic Transmission .... and movethe transmission gea-r Selector lever

Fluid (E4AZ- 1.9582-B) transmission oil or equivalent, through all of the gear ranges allowing sufficientBefore adding any oil, be sure that the correct type will time for each position to engage. Securely latchbe used. the transmission gear selector lever in the park

Under normal circumstances, you do not need to position, fulIy set the parking br_ke and leave thecheck the oil level of the transmission, since your engine running. -_._."_.:: ',i_vehicle does not use up transmission oil. However, if 2. Wipe off the oil level indicator,_'p., pull the oil levelthe transmission is not working properly -- for indicator out and wipe the indi_'tor end clean. Putinstance, the transmission may slip or shift slowly, or the oil level indicator back.!nto the oil filler tube ....you may notice some sign of oil leakage -- the oil level (7A228) and make sure it is fully.seated. Pull theshould be checked. __i: " oil level indicator out and read the 0il level..

It is preferable to check the transmission oil level at " _normal operating temperature, after approximately 32km (20 miles) of driving. However, if necessary, youcan check the oil level without driving to obtain anormal operating temperature if outside temperaturesare above 10°C (50°F).

. . 1994 Econoline/F.150. F-250, F-350/Bronco/F-Super Outy Powertrain/Otivetrain Aug 1993

Page 533: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-17 Tran=mllelon, Automatic, C6 07-01B- 17Im

'; DIAGNOSIS AND TESTING (Continued) " .

.. ,.,, _:,,',,- ",,;'_Transmlsslon.Cbld_. , , ._i_ " . , ; 1. Make the normal,ell'check according tothe ,,,!',When checking oil at normal operating temperature, aboye procedure: ., theoil level should be within the crosshatchedarea 2; ' Observe color and odor of the oil.lt should be

• : (F-Series) or HOT area (E-Series) on the oil level dark reddish not brown or black• ':. indicator.,When:the vehicle has not,been driven, and.;' ' " ' '_,outsidetemperature is abo_/e 10°C (50°F). the oil e, A burnt odor can'sometimes indicate that there

, ' level should.be between the holes (F-Series) or COLD ' is an overheating conditionor clutcPi disc or. area (E-Series)on ,the oil level indicator, band failure.

•' .... 3..' Use a,clean; lint-f_ee ragto wipe:the oil level', indicator'.:Examine;thestain for.evidence of solids

' .....(sPecks of _anykind)iand, for,co01ant,signs (gem or' ' varnish?on:Qil.:level!ndicator): ' ::.__:.

....... _, _ OIL:LEVELAt-NORMAL', '",.:,: . OII Lev'el:Hlgh;or'Low_ ,,,.... :., ' :.,..."'-:,..,

"': !'!_ ' _ r"_'rI DeE RATI N G TE M PE RA]" U RE "_:''''" "

"166:c re 7.z,cIIS0'F:TO,. " " Aioil level that is too high will cause the oil.to become'. •;. '1'_:0 • - , .. • aerated: Aerated oil will causelow control pressure.

-- o ,-] O_LLEVELWHEN" . and the aerated oil may be forced out the vent.C 1 VEHICLE HAS NOT SEEN

o | On,yEN.ANDOU[S_OE LOWoil level may be the causeof transmissionLO De-icer ,o .J TEMPERATUR_ " _. slippage.or_non=engagement,,Lo.w,levelma¥ indicate., is ABOVE10C(S0F) . oil leaks'that_:c'ouldlcause tr,ansrnissi0n damage

,,,_-" 0RIVE MARK ' . '.. .

T .. i OIILe,veFHIgh_Be:fore:Start ngEnglne,,OKDuringNormal CheckE.SERIES F.SERIE$ Dl1822-8

•, ,, Itis normal,for th'e.oillevel.to behigh prior tothe engine"Add oil in 125L (.I./2.piht)increments through theoil starting• The_torquecohverter,will dra ndue to the

• - _filler_,tubeto bring, the.level.to the'correct area on the "-,absenceof a::drainback_valve: All clutch assemblies ofoil'filler .tube:-Ifan overfill occurs;, excess oil should be .:',the transmission,.will dr.a n to the sump also. causing oil.

i removed by draining..Refer to:,TransmissionOil Drain , level to b_ high• , .,:.,ah'd,Refill in!this section.., , . ....... ............... ' ' ''. _'' . " "

: .': _:. ':,_' "_:,'"_:'' : ","._'::'!"i-' , ..; _', :'._":',:_i'"'_ "'_

Transmission Oil LeakageChecks

Transmission Oil Condition,Check 1. Check the speedometer bore plug at theNOTE: Oil used with the automatic transmission extension housing (7A039). Replace or re-sealcontains a detergent which retains in suspension the plug if necessary.particles generated.during normal transmission use. 2. Leakage at the oil pan gasket often can beThis characteristic may result in a dark coloring of the stopped by tightening the attaching bolts to theoil and does not by itself indicate malfunction or need proper torque. If necessary, replace the oil panfor repair, gasket.If specks are present.in the,oil or thereis evidence of-,.... 3. Check the lube oil filler tube at the case. Ifcoolant, the transmission oil pan.(,7,A194)imustbe,,:::,: -,..... . leakage is found;.install a new'O-ring The oil fillei" 'removed for further inspection; If oil.:contamination,or-:-:., " tube brackets should align properly andbetransmission failureis;(',onfirmed:by:further'ev denOte.of::.._, attached to thetransmission or engine locations.coolant or excessivesolids,in the transmission oil pan,.the transmission must be disassembled and 4. Check the oil cooler tubes and fittings on thecompletely cleaned and repaired. This includes transmission and the transmission oil cooler in thecleaning the torque converter (if applicable) and radiator (8005) for looseness, wear or damage. Iftransmission cooling system. Do not perform any leakage is found, tighten the fitting, or replace thefurther checks before cleaning and repairing the damaged parts.transmission.

1994 Econoline / F- 150. F-250. F-350 / Bronco / F-Super Dut_ Powertrain / Orivetrain Auj 1993

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07-01 B- 18 Tranlmlsslon, Automatic, C6 o 07-01 B- 18

., DIAGNOSISAND'TESTING (Continued).:: .... :. " . . • ' ..

OllCoole'r Tube Fitting= '_. , ., , ,. TorqueLImlts, Tran=mlsslon ,' • . "' " _ . ....... ' f ..-:.. _._.:

Redletor Tt,,n,,mleelon 011CoolerTubsNut

I. TrensmlHIon N.m Ft-Lb N.m Ft-Lb N.m Ft-Lb• ,z'I

C6 I 1-16 • 8- t2 24.31 18-23 t7-24 12-18 :4.

, NOTE: 13o not_mistake radiator rust inhibitor coating When a converter drain plug leaks, remove the drain ,:,,:.....!as evidence oi,,,transmission oil cooler leakage, plug with a six-point wrench. Install a new drain plug.",,5. Check t_'b engine coolant in the radiator. If 15ghten the drain plug to 11-37 N.m (8-27 ft-lb).

transmission oil is present in the coolant, the • Oil leakage in the converter housing.area may also' - -." transmiSSion oil cooler in the radiator is probably be caused by engine oil leaking p;ast the rear main

leaking.' bearing, from oil galley plugs po_er steering oil""_WARNING:"DONOTREMOVEARADIATORCAP leakage from steering system or,'_t_:ansmissionfront:".,:,FROM'A HOTCOOLING SYSTEM. ALLOW oil pump seal. Be sure to determine the exact cause

': VEHICLE COOLING SYSTEM TO COOL DOWN of the leak before starting repair, procedures.

.; ,.BEFORE MAKING THE NEXT LEAKAGECHECK. • Oil-soluble aniline or fluorescent dyes premixed at[:6. Check further for leaks by disconnecting the oil the rate of 1 / 2 teaspoon of dye powder to 0.23 liter

cooler tribes from the transmission oil cooler ( I / 2 pint) of transmission oil have proved helpful infittings a_d applying 172-310 kPa (25-45 psi) air locating the source of oil leakage. Such dyes may

•. pressure:lo the fittings. Remove the radiator cap be used to determine whether an engine oil orto relievethe pressure buildup at exterior of the. transmission oil leak is present, or if the oil in thetransmission oil cooler tank. If the transmission oil transmission oil cooler leaks into the engine coolant

,- cooler isqeaking'and / or will not hold pressure system. An ultraviolet lamp must be used to detect;,. (watch for bubbles through radiator cap opening), the fluorescent dye solution.

• ,_ the transmission oil cooler must be replaced. OII Leakage In Torque Converter AreaTransmission oil cooler replacement is describedin Section 03-03 In diagnosing and correcting oil leaks in the front pump

..... ""_ "_'_ ' _ " ; " and torque converter area. use the following7. Replace either or both seals if leakage is found at procedures to locate the exact cause of the leakage, ..

either the throttle control outer lever seal or the Leakage at the front of transmission, evidenced by oil ::_manual control lever seal. around the converter housing, may have several '

8. Inspect the pipe plug on the left front side of the sources. By careful observation it is possible totransmission case. If the plug shows leakage, pinpoint the source of the leak before removing the

_ _tigl3ten thep[ugto spec f cations. If leakage .... transmission from the.vehicle. The paths which the'oilcontinues, replace the plug. Inspect the throttle takes to reach the bottom of the converter housing arevalve pressure plug on the right rear side of the illustrated. ' "case. If the plug shows leakage install a newdrain plug and tighten the plug to 9-16 N.m(79- 141 in-lb) ...... ,_._,., i.....

....... _,_-,.,: .... L,.

_ _ 1994 Econoline/F-150,F-250,F-350 /Bronco/F-SuperDutyPowerttein/OdvetralnAug1993

Page 535: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-1g Transmission,Automatic,C6 07-01B-19_"rBIBi I I .....

_DIAGNOSIS.AND_ TESTING (Continued) ..... ,

:,.,.i:_ _:" ,,;:_,:_:_;ConverterHouslng:OILLeaks_ ,_,.,..,._:.......

!

"r

. _ . .,..:., ':. . .?._,. ,._. ._ • _ •

®

02SO4-F

• Part Part '.. .....Item, Number Description Item Number Description ,_

1 6303 Crankshaft 5 Converter Housing

2 7A248 Front Pump Seal Leak (Part of 7005)3 58619-$2 Front Oil Pump to Case Bolt 6 87650-S Converter Drain Plug Leak or

Leak Converter to Flywheel Stud

4 7A 136 Front Oil Pump Gasket Leak Yield Leak7 6375 Flywheel

(Continued) 8 7902 Torque Converter9 670 t Crankshaft Oil Seal Leak

Oil leaking by the front:oil'pump seal lipwill tend'to Oil leakage from the converter drain plugs ormove along the drive hub and onto the back of the converter-to-flywheel stud weld will appear at theimpeller housing. Except in the case of a total seal ' outside diameter of the torque converter on the backfailure, oil leakage by the lip of the front, oil pump seal face of the flywheel (6375). and in the converter(7A248) will be deposited on the inside of the housing only near the flywheel.

converter housing only, near the outside diameter of Engine oil leaks are sometimes improperly diagnosedthe housing, as transmission front oil pump seal leaks. TheO leakage by:the outside diameter of the front oil .,,,_._ •, following areas of,possible leakage.should also be ......

. _ _:,-. - pump sealand front oil pumpbodywill follow:thesame;_::, checkedto determine if engine oil leakageis causing . ,,path which the leaks by the front oil pump seal follow, the problem:

Oil that leaks by a front oil pump-to-case bolt will be a. Leakage at the valve cover (6582) or rear intakedeposited on the inside of the converter housing only. manifold gasket may allow oil to flow over the "Oil will not be depositedon the back of the torque converter housing or seep down between theconverter, converter housing and cylinder block, causing oilLeakage by the front oil pump-to-case gasket may to be present inor at the bottom of the convertercause oilto be deposited inside the converter housing, housing.or it may seep down between the front of the case and

'-- converter housing.

1994 Econoline/F- 150. F-250, F-350/Bronco/F-Super Duty Powertrain/Orivetrain Aug 1993

Page 536: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-20 Transmllslon, Automatlc, C6 07-01B-20 :,:. I III • ""lli " "" I ' '

_'DIAGNOSIS AND.TESTING (Continued)., i" . ........... .,

, :,%

b.., Oil,galley plugleaks.will allow'oil, to flow-down the • " ,",Transmission OilCooler FlowTest",': • " "rear'face of the cylinder block to the bottom of, NOTE: The transmission linkagecable adjustment, oilthe converter housing• level, and line pressure must be within specifications

:c. Leakage_by the crankshaft seal will work back to before performing this test. Refer to service -_the flywheel, and then into the converter housing, procedures as outlined. ,, ..

'!!Oil leakage f_'m other areas, such'as the power ._ 1. Remove oil level indicator from oil filler tube.

. •steering system foi'ward of the transmission, could 2. Place funnel in oil filler tube, ,, •._,_.,cause oil to be_!present around the converter housing ,,,

_due to blow ba;ck or road draft. The following 3. Raise vehicle on hoist and position suitable safety , "__• :,:procedures sb.ould be used to determine the cause Of stands under vehicle•/_the leakage b_fore any repairs are made. 4. Remove return oil cooler tube (rear fitting) Irom :.,._

• . Remove_the transmission oil level indicator and fitting on transmission case. Refer to In-Vehicle'_ note the_olor of the oil. Original tactory-till oil is Service in this section,

dyed red,to,aidJn determining if leakage is from ' 5. Connect one end of a hose to'tbe return o I cooler.the engine oc transmission. Unless a considerable, tube and route,the other end of_tlie hose up to a

i::";.,, amount of makeup oil has been added or the oil point where it can be inserted into the funnel at;,_ has been changed, the color should assist in the oil filler, tube..:. pinpointing the teak. Since road draft may cause,;, leaking pQwer steering fluid (also dyed red) to be 6. Remove safety stands and lower vehicle. Insert•: present on the transmission, this leakage, if end of hose into funnel.

-._.. presenti_hould be eliminated before checking the 7. Start engine and run at idle With transmission intransmission for oil leakage. NEUTRAL.

2. Remove_the converter housing cover. Clean off 8. When oil flowing from hose is solid, a liberal_, any oil frSm the top and bottom of the converter amount of oil should be observed. "Liberal" is-:. housing/front of the transmission case, and rear described as about 1 / 2 quart delivered in 30

4 • • .':_ face of th,e engine and engine od pan. Clean the seconds. If a liberal amount is observed, test is" converte_ area by washing with a suitable completed.

_.,_ non-flammable solvent and blow dry with 9. If flow is not liberal, stop engine. Disconnect, hosecompressed air.,, ,:.., ,.__,.,,,;,. -: _. from return oil cooler tube and connect it to the

3. Wash oui the converter II'0usincj. the ir0nt of the converter-out line fitting (front fitting) onflywheel and the converter drain plugs. The transmission case. ":.&

converter housing may be washed out using 10. Repeat steps 7 and 8. If flow is now liberal, refer "_cleaning solvent and a squirt-type oil can. Blow all to appropriate section for diagnosis and cleaningwashed areas dry with compressed air. of the transmission oil cooler and tubes, If flow is

4: _ .Start and run the engine.until the transmission .... not liberal., service front pump assembly-and/orreaches its normal operating temperature• the torque converter assembly• ,_,,Observe-the back of the cylinder block and top ofthe converter housing for evidence of oil leakage.Raise the vehicle on a hoist and run the engine at

fast idle. then at engine idle. occasionally shifting Engine Idle Speed Checkto the drive and reverse ranges to increasepressure within the transmission• Observe the ff the idle speed is too low. the engi_e,_willrun rought_,. 'front of the flywheel, back of the cylinder block (in An idle speed that is too high will ca_s'e the vehicle toas far as possible), and inside the converter creep, have harsh engagements and harsh .,

• , housing and front of the transmission case. Run closed-throttle downshifts.the engine until oil leakage is evident and the "::_;Referto the Powertrain Control/Emissions Diagnosis 'probable source of leakage can be determined. •Manual" if you suspect an idle problem.

Torque Converter Leakage Check "On vehicles equipped with an Exhaust'Gas

If welds on the torque converter indicate leakage. Recirculation (EGR) system, it is important to check A

remove the torque converter and make the following the system for proper operation and for restricted or :,,!check, leakageconditions.

Assemble a Rotunda 021-00054 Torque ConverterLeak Test Kit or equivalent to the torque converter.Test the torque converter for leaks following thedirections supplied with the kit.

4 Can be purchased as a separate item•

"-'_, 1994Econoine/F.150 F.250, F.350/BtoncolF.SuperDutyPowerltAinlDrivetrainAug 1993

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O7-OIB-21- Tranemlnlon, Automatic, C6 : O7-O1B-21 "•'"" II I II

,' :.'DIAGNOSIS AND TEST!NG(Continued) • ' ".,, ,,

' !,"J!Shift,Llnk'age_Check_; _,'_,',_.... :.: ' : .... ,i!:;: . e Internal hydraulic leakage'atthe manualshiftvahie., .

, Downshift Linkage' "' , can cause delay in engagements and/of slipping ,,,.,

.while operating if the external linkage is notWith the accelerator, pedal held in the.wide-open correctly adjusted.throttle'position (at the floor); check throttle body • " Pleasenotethat the column-m0unted PRNDL is: (9E926)and linkage:travel to besurethey have .e,

. adjustable: Once the:transmission.shift cable has -,...... '.. be,contactedattainedfull wide-openthrottle.,bythe throttlelinkageTheandthi'°ttlethere:St°PmustbemUSt., " . .,beenpr,opedy,adjusted;thePRNDE can be adjustecl

' " ,:; _-,.:.... J_:movementleft'in:the.downshift linkage.Be sure'the": ' _' ' ,,-_.tocorr,espond,exactly.,tmthe:transmission shift, •v, downshiftfinkagereturnspring is connected and the " ..... cable,adjustmer_t. ,: i , , ,. . _ :-,.,.. • i " .

. downshift lever returns to a closed position. . ' Accelerator,Linkage'and 0pei'atio_.

•, For Multiport Fuel Injectionsystem kickdown " .. The linkage must be free:ar_dmust'return to ii::liewhen,procedures, referto Section.,lO,02., ' releas'ed:;Refer toSection._10-O24_r.acce erator

• -:Manual Shift Cable, - "." ,,' " linkage adjustment:. '

• :This is aCRITICAL adjtJstment:';Be,,sijre,theDdetent ira., •:.;':.the transmission corresponds exactly with the Dgatestop in thesteering column or console, Refer toSection07-05 for adjustment procedures•

'' ....... L' " ' ' "i"

:"Shift Point Road Test 'ClosedT,hrottle Downshlfts '

.... _This checkwill determine If,the governor . ' ,: Checklhe.closed throttle downshift from third to first-.,,pressure and shift_control_valves arefunctionlng " .' , -by coasting down.,from about 48 kin,(30 mph) in third' properly. ' gear.,The shift,shou d occur within.the.limits listed in

' "' ,,v.Check;the;minimum.throttleupshifts in D(drive). ,The ' the specifications..-.:,transmission,shouldbegin.infir, stgear,:shift',tosecond; • : ..ManuaI.Downshlfts ., , ' . • . •

, ,'.... and then;shift to third,within theshift, points listed in ' - When the:gear selectoi, lever is'ati2 (se'cond)_:the.'_" _"."• . Specifications,;at*the endof this section•transmission can operate only in second gear.

Forced Downshifts With the transmission in third gear and road speedWith.the transmission in third gear, depress the. ..... over 80 km (50 mph) the transmission should shift toaccelerator pedal through the detent (to the floor)• The second gear when the gear selector lever is,movedtransmission should shift from third to second unless from D (drive) to 2 (second) or 1(first)•

vehicle is traveling above downshift lock-out speed, or The transmission will downshift from second to third tothird to first. (perform at 15-20 mph). first gear when this same manualshift is made below

approximately 30 km ( 18mph).

Refer to the band application chart to aid in diagnosisof transmission conditions.

• . . , ,

? :'i.',I-.:"C6'AU:TOMATIC,TRANSMISSION:CI_U_TCH AND BAND APPLICATI.ON SUMMARY

Forward Planetary Gearaet Rear Planetary Gearaet

Gear Holding Members Driven Held Output Driven Held . Output

Manual Low. 1' Forward Clutch ' . Forward Ring' ForwardAssembly Gear Planet" Sun Gear Sun Gear Rear Planet Ring Gear

Forward Clutch

D Low Assembly and Forward Ring Forward Sun Gear Sun Gear Rear Planet Ring Gear,

One .way Clutch Gear Planet = :

Forward Clutch,

D Second Assembly and Forward Ring ' Forwardor 2 Gear Sun Gear Planet Effectively In Neutral

Intermediate Band

Forward ClutchSun Gear

Assembly and ForwardHigh Direct Clutch Forward Ring None Planet Turns As a Unit

Assembly Gear

Reverse Clutch

Assembly and Rear PlanetReverse Direct Clutch Effectively In Neutral Sun Gear Ring GearCarrier

Asser_bly

The front planet carrier is actually turning with the output shaft, but at a slower speed than the input sh_tt.

1994 Econoline / F- t 50, F-250. F-350 / Bron co ' F-Super Dut_ Pow ertrain / Oriv etrain Aug 1993

Page 538: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B-22 Tranemltslon, Automatic, C6 07.O 1B.2_I I "

.':DIA,'GNOSIS'_AND:TESTING, (COntinued): -..... '"'., "

,-_Governor... ,.-_ . Check .' . ...-, . . ' A constant vacuum is.supplied totheVacuumregulator_, " ' '""_:.;,The governor can.be checked at the same rimeas the " valve by an engine driven vacuum pump which alsoControl Pressure Test is performed and in the same delivers vacuum to other accessories. The vacuum

, .manner. regulator valve regulates an output vacuum signal tothe transmission's throttle valve control diaphragm . ,: :,,_,

.NOTE: After each test, move the gear shift lever to N which is proportionalto the throttle position.As the::_(neutral)andr,unthe engineat 1000 rpm to cool the throttle is opened, the regulated vacuumfrom the

transmission, valve drops.

'_,_CAUTION: Never exceed 96 km (60 mph) Should a malfunction occur in the vacuum regulator _:_;;_.speedomet_r speed, valve, the valve will cause a 0 vacuumsignal to be sent;'NOTE: Connect throttle valve control, pump to to the vacuumdiaphragm whichwillcause delayed•_diaphragm Witha hose long enough to reach up to the and harsh shifts to occur.

_,driver's seaLi,',', Anytime delayed or harsh up-shifts_ai'eencountered'. _'_i::1. Raise the vehicle with anaxle.or, frame hoist so the performance of the vacuum reg_i'ator valve should: -

:_; .. that the rearwheelsareclear..of the floor.- be checked prior to performing any!tcansmission "repairs. Also check vacuum line to _n_dfrom the valve_;._"2. Disconnect and plug the vacuum line io theto transmission for proper connection or damage

:;_i throttle yalve control diaphragm. Connect Should the vacuum regulator valve be replaced.or:the_,,,. Vacuum'_PumpD83L-7059-A or equivalent to the': throttle _lve control diaphragm, fuel injection pump be removed, the valve must be

,_:_, adjusted to specifications. Refer to adjustment_,,,113 Place th'e,transmission, in D (drive), no load on the procedures in this section.

engine a,ndapply 10 inches of vacuum to the, ,.. throttle valve control diaphragm. Increase the "' , speed slowly and watch the speedometer. Check

the mph;at which the control pressure cutback Line Pressure Test _ Testing Procedure;. occurs, It should occur between 16-32 km (10-20mph). There are two methods of performing the control

pressure test. One is to perform the test using the•'The governor_is good if the cutback occurs within engine vacuum. The second method is to usa a: these specifications. If the cutback does not occur remote vacuum source such as the one provided in,,within specifications, check'._sl_ift_speed_-to;vedfythat the distributor tester or a hand-operated vacuum,,'it is the governor and not a siuck cutback valve, thenrepair or replace the governor, pump.

I Vacuum Regulator V_alve(VRY) (Z.3L Diesel ............The vacuum regulator valve is used on E-250-E-350and F-250-F-350 Series Vehicles equipped with.7.3Ldiesel engines.

On 7.3L diesel engine vehicles equipped with a C-6 ......_:_-_,,.,-automatic transmission, a vacuum regulator valve isincorporated to provide a vacuum signal which isproportional to the throttle position to the throttle valve

, control diaphragm of the transmissionl The vacuum_.regulator valve isnecessary to provide a vacuum .... ' ........ ",_signal to the C-6.transmission because the diesel ......

•engine has no vacuum. The vacuum regulator valve is , •bolted to the fuel injection pump and is actuated by thethrottle lever.

""_"" 1994 Econoline / F- 150. F.250. F.350 / Bronco / F-Super 0uty Powertrain / Drivetra n Aug 1993

Page 539: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-23 Transmission, Automatic, C6 07-01B-23Ill I

', ." DIAGNOSIS ANDTESTING •(Continued)• :. '

"/" "' " ",.?.LinePressuce Te_stD,iagnomtlc:Chart_ _,_,:::,.:: .-.4

..... _..........._-.......-I I _• I_LOW AT IOLE HIGH AT IDLE ., , OK AT IDLE

IN ALL RANGES ' iN ALL•RANGES • _"' : IN ALL RANGES

..... I I 1, ' RESTRIGTEDINTAKE,;_;.. ,.. ,.r..: ',......,_. / , . , -LOW_ AT . . ' OKATIOIN.,

• ".: ,'rHR":'-'EE , VACUUM BUT LOW "VACUUM • "- , , AT.t IN. VACUUM

OIL COOLER':TUBES; LOOSE " CONTROL DIAPHRAGM ' " I IMAIN CONTROL VALVE UNIT. MANIFOLD VACUUM

8OOY'OR REGULATOR TO LINE. OR THROTTLE VALVE I THROTTLE VALVE I I EXCESSIVE LEA)(_GE. I, EASE'BOLTS, EXCESSIVE CONTROL ROO.'STICKING JCONTROL DIAPPIRAGMJ J Low' PUMP CAPACI'TY ILEAK.AGEcAsE;MAININ'FRONTcONTRoLPUMP, REGULATORvALVE(sLBOOST _ ' VALVECONTROL'RO0" I

I UNIT OR.THROTTLE., I.:1;RESTRICTED OIL PAN

r , I ' _' 'SCREEn.", • :VALVE'BODY OR A STICKING , ,

CONTROL PRESSURE' ' REGULATOR VALVE. ........

...... ........iii ILINE PRESSURE TEST , .:

ILO'_V IN

I.........................I I i I I [

P N O 2 1 R

I L I

CONTROL I I JICONTROL CLUTCH CLUTCH CLUTCH CLUTCH

VALVE BODY VALVE BOOY AND/OR ANC)/OR ANO/ORINTERME01ATE REVERSE SERVO

SERVO CLUTCH OR

DIRECT• • " CLUTCH

CDZ93S-D

• Engine Vacuum Procedure -- Line Pressure Test If the shifts do not occur withinlimits,or the

• When the throttle valve control diaphragm is operating transmission slips duringshift point,use the following,'properlyand the manual and downshift linkageis -.., ". . procedure to determine whether the engine. , ,

: '. • adjusted properly,.all.the transmission shifts,-, transmission, linkage, throttlevalve controldiaphragm(automatic andkickdown) shouldoccur withinthe road or maincontrol valve body is causing the condition.speed limitslisted inSpecifications at the end of thissection.

1994 Econoline / F- 150. F-250. F-3501 Bronco / F-Super Duty Powettriin / Drivetr,= in Aug 1993

Page 540: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-24 Transmission , Automatic, C6 _ 07-01B-24II HI II

• ;DIAGNOSISANDTESTING"(Continued)_"; -,, _ . ..... ' " "

CAUTJON:,Pressure gauges_affect_the shift, -'. , . .:4. If theengine_idlespeedis not,within:'_'_/:_'. ' ' ' :.)-"_' quality of the transmlssion:_Care shotJId:betaken. ' specifications, refer to the Powertrain : "

NOT to accelerate or decelerate rapidly. Possible ControlEmissions DiagnosisManual_ forrepair •'itransmission failure could result, procedures. Also check throttleand downshift

.! 1. Attach a tachometer to the engineand a Rotunda linkages for bindingconditions. .:._; Vacuum_/PressureTester 059-00008 gauge or • If linkage is satisfactory, check for vacuum

equivalent.tothe transmissionvacuum line:atthe leaks inthe throttle valve controldiaphragm,:-_ manifold vacuum po_t. and its connecting tubes and hoses• Check all," _: other vacuum operated units (such as the _'_.:i_:_ MANJFOLO_UUM power brake) for vacuumleaks. Refer to the.,._i. .LIfJE HO_;'E appropriate brake section in Group 06.

/ -_

/ "__,,_.t._rr_nG , , Vacuum Pump Procedure -- Line Pressure Test .

/;_ ' _' Disconnect and temporarily pl_g the vacuumline.':i_'_' ':?_' J _____. _ _ I. at the throttle valve control'di_hragm: Attach'a ' ""

2. Apply both the parking and Service brakes_'-Start,_ the engine and vacuum pump.

i!. _ii/_ 3. Set the vacuum at 15 inches, read and record the_.i _ VACUUMMANIFOL£)PORt" line pressure in all manual control lever positions..,._._, Run the engine up to 1000 rpm, and reduce the

vacuum to 10 inches. Read and record the line

pressure in D, 2 and 1. Keep the engine rp_ atre Roru_JOAVACUUM, 1000 and reduce the vacuum to I inch: Read and

:_' -"-'PRESSURE TESTER05900008 record the line pressure in D. 1,2 and R.

VACUUMGAUGE 4. Refer to the two line pressure diagnostic guides in

_:. THROTTLEVALVECONTROL the Line Pressure Test chart to show what__. DIAPHRAGMCONNECTtON'• components are inoperative when the line ".... ..... oT_e_.e pressu_'e test is not within specifications. Do not

proceed with the main diagnosis guide untilyou . ,;_2. Attach a pressure gauge to the line pressure have made any repairs, as required, and the line

outlet at the transmission, pressure is within specifications as listed in .Specifications, at the end of this section.

" " Vacuum Supply Test _ Line Pre_ssureTest_ .-- =: - - ..... The vacuum supply to the throttle valve control

\ l s_iii_ _ diaphragm and the diaphragm itse,f must be checked.

PRE 1, Disconnect the vacuum line at the throttle valvecontrol diaphragm and connect;it to a vacuum

gauge. With the engine idling,_t_ gauge musthave a steady acceptable vacuum reading for the

altitude at which the test is beingperformed.

• If the vacuum reading is low, check for a

__,-_ vacuum leak. If the vacuum reading is OK,.rapidly accelerate the enginemomentarily "while applying the service brake and with the

D7390-8 transmission in PARK. The vacuum readingmust drop rapidly at acceleration and return

3. Firmly apply the parking brake and start the immediately, upon release of the accelerator. Ifengine, the vacuum reading does not change or

changes slowly, the transmission vacuum lineis plugged, restricted or connected to areservoir supply.

5 Canbepurchasedasaseparateitem.._, 1994Econoline/F-150.F-250.F.3501B_oncolF.SuperDutyPowertran/OrivetrainAug1993

Page 541: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07,-018,25 Transmission, Automatic, C6 07-018-25' mm

:" DIAGNOSIS ANDTESTING (Continued) . :

_i;_:.',, 'o_. 2._,_-i_°Corr'ect,asrequired.:. ,. : " . ._ Vacuum Diaphragm, Test, Off-Vehicle:.,1.. Tocheck the throttle'valve control diaphragm for.,-.diaphragm.leakage, remove the unitfrom the

transmission. Use a distributor tester equippedwitha vacuumpump, Rotunda VacuumTester02.1,000.1A or.equivalent..Set the regulator knob........

: untilthe vacuurngauge reads,18 inches with'theend ofthe vacuumhose blocked Off.

• 2 .... Connect-,.thevacuum hose to the manifold vacuum

" : por,t,as_s.hownpreviously, f,the gauge still reads

.... - 18_inches;' the: thro.ttle-valve control diaphragm is•not. eaking.:A second, leakage check can bemade, as,:the hoseis,removed from the

, :' ,transmission. Hold a finger over the end of the................ o4to4.e_ ., "control rod. Whenthe hose is removed, the

• Refer to.the two line pressure test diagnostic cha_'tSto . internal springof the vacuum unit should push the:,.show what components are inoperative-when the line, throttle control valve rod outward. If the vacuum

,. pressure test is not within specifications. Do not diaphragm needs replacing, install a'new unit'-,,.-proceed with the main diagnosis guide until you have modu ator.assembly:.,that has'been,released for" _made any,required repairs, and the line pressure is ' _.... _service_Reinstall.the:vacuum th¢0'ttle valve• within specifications as listed inSpecifications• at the ' " diaphragm"heatishield _Throttle qalve control• " ,diaphragmassembly identification is given,at endend of this section, "_ ' ' -_' .

of this section.:Vacuum Dlaphr.agm Test, On-Vehicle

NOTE: If automatic transmission oil;is present in the.....,:ivacuum sideofthe.tnrottle valvecontrol diaphragm or ....

,. ..... in-the vacuum hose, the,throttle valve control ',:,Stall Speed Test "

:_ dial_hragm is leaking and must.be replaced.- ..... NOTE_-,T.heline.pressure testingprocedure MusT,be _• ,.-t. To check the throttle,valve,control diaphragm,, performedprior to,the following tests.:"_, ' ' .

, , start,the vacuum pump'and set the regulator knob Refer to Specifications in this section for stall speedso that the vacuum gauge reads 18 inches withthe end of the vacuum hose blocked,off.. ' specifications.

2. Connect the vacuum hose to the throttle valvecontrol diaphragm. If the gauge still reads 18inches, the throttle valve control diaphragm is notleaking• If the reading does not remain at 18inches, but drops, the throttle valve controldiaphragm is leaking. Remove vacuum throttlevalve diaphragm heat shield and replace thethrottle valve control diaphragm. Reinstall.throttlevalve control diaph_'agmheat..shield_._,,;,!:;_......_' , . ..

199_4 Econoline/F- 150. F-250, F.350t Bronco/F-Super Duty Powertrain/Drivetrain Aug 1993

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07-018-26 Transm!selon,Automatic,C6 07-01B-26, o i

StaltTest Diagnostic Chart ..... '..... _ 'L

_' I PI:RFORM LINKAGE CHECK J

,L NOT OK OK

t

*_*' LEVEL NOT OK CONTAMINATED * *

"_:j

"_':;1 F #'_: I STOP'ANDREPAIRREMOVE'DISASSEMBLE, CLEAN I . ., .:.,;.!;_ 8RING OIL LEVEL SET'_,/EEN ADO

"; I ,_v.;AND FULL ON OIL LEVEL INDICATOR I -TRANSMISSION._ FLUSH IOK

TORQUE CONVERTER A,ND I '_|

'_'" ' *"/'_' I TRANSMISSION OIL COQEER Ir " _7 .WHEN OK "_

;_ .I *'4}, 1,- ADJUST 8AND C6 (AS A MATTER OF NORMAL MAINTENAt,=CE. ADJUSTING THE BAND IS NOT NECESSARY)

i. I STALLteST j

-_ " SELECTOR POSITION_ I _C; STALL SPEEDS HIGH STALL SPEEDS LOWg

,_' ., "_"- O ONLY FORWARD CLUTCH OR TORQUE CONVERTER STATOR :_i"

,,; _-':-.."' - ONE.WAY CLUTCH ONE.WAY CLUrCH. INCORRECT 'TORQUE CONVERTER OR E_LG_NE"_'_I"F' ",:.:._-._-. =,S ..._,.'. r-._ . PERFORMANCE

O. 2 & I FORWARD CLUTCH OR TORQUE CONVERTER STATORONE.WAY CLUTCH ONE,WAY CLUTCH. INCORRECT !

TORQUE CONVERTER ORENGINE PERFORMANCE

O. 2, 1 & R INCORRECT OR FAILED TORQUE TORQUE CONVERTER STATOR. : . ..... CONVERre R - ONE .WAY CLUTCH, INCORRECT

TORQUE CONVERTER OR ENGINE .,PERFORMANCE

R ONLY REVERSE CLUTCH TORQUE CONVERTER STATOR

ONE-WAY CLUTCH, INCO_R.ECT"TORQUE COI_IVERTER OR_ENGINE

PERFORMANCE _,(_. _

• ,=OR DEFINITION OF CONTAMINATION SEE "TRANSMISSION OIL CONDITION CHECK." IN THIS SECTION "_" CDZ828-J

Air Pressure Tests A no-drive condition can exist, evenwith correct

NOTE: When you have a slip problem and do not know transmission oil pressure, because,_ __:_.:^.Drinoperativewhether it is in the main control valve body or in the clutches or bands. On automatic Lr.,n=H,==,vn=,

an

hydraulic system beyond the main control valve body, , erratic shift can be caused by a stuck governor "_the air pressure tests can be very valuable, primary valve. The inoperative units can be located

through a series of checks by substituting air pressureTo make the air pressure checks, loosen the for fluid pressure to determine the location of thetransmission oil pan bolts and lower one edge to drain malfunction.the transmission oil. Remove the transmission oil pan

body ,,.,--__,,z°=_°m_'h'.The When the gear selector lever is at D (drive), 2and the main control valve,._.._ ..,_;nnn'=r_l'iv= clutches or bands can be located _'- (second) or L (low) a no-drive condition may beint;roducingair pressure into the various transmission'7 caused by an inoperative forward clutch or one-way

clutch. Failure to drive inR (reverse) couldbe causedcase passages,.i J

by a malfunctionof the reverse clutch.

_" 1994 Econoline I F- 150, F-250. F-350 / Bronco / F-Super DutyPowertrain / Orivetrain Aug 1993

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07-01B-27 Transmlulon, Automatic, C6 07-018-27

•-, .DIAGNOSIS.ANDTESTING(Contlnued) . .

•":" ' 'i? .lease Fluid Passage Hole Identification -. ....... . Reverse Clutch ."- - -' • :_ ......

"-...... '. .... • ' "" :'" :- _ :": ; "_":" " " Apply air pressure to the'reverse clutchapply::A dull " "thudindicates that thereverse.clutch piston has

'moved to.the applied position. If no noise is heard,place the fingertips on the case at reverse clutch and

.. again apply air pressure to:de!act movement of the.clutch piston. : . . ,

• " . ...... Forward.Clutch .... .

:Apply air:pressure, to:.the transmissioncase front='clutch.cylinder passages:-:Adu ,thud.can be heard:when:theclutch ;piston, is applied. Ifnon0ise is heard,

-,_,place:the finger:tips_on:the::inputshelland'again apply.....air pressure'tO the'.fr.ont:clutch,"cylindffr:passage.

. Movement of thecl(Jtch piston can be felt as.the:clutchis applied.

Governor

Appty air pressure:to the control' pressure_to governor•passage:an d listen,fora, shar.p.clicking_0r whistlingnoise-',.T-he.noise_ndicates..governor.pdmary valve

,movement.

,Intermedlate.Servo

.. Hold:the,air, nozzle in.theJront'servo apply tube or the' inter,mediate servoapplypassages: Operatibn of the

,:, servo is' indicated,byla'_tightening of the front;,_.intermediate:band around,thedrum' Cont nueto apply •

:,. '- _ air pressure.to theservo,apply,tube or,passage., and:,,introduce _airpressure into, the front re ease,tube or the ::,, intermediate,servorelea.s B passage:_The, frontor ;_,..... :,,

intermediate servo should release the intermediate ,band against the apply pressure.

0739z.c IN-VEHICLE SERVICE

Part Oil Cooler LinesItem Number " Description

When oil leakage is found from the transmission oil1 -- Servo Apply (Part of 7005) cooler, it must be replaced. Cooler replacement is2 -- Servo Release described in Section 03-O3.

,, :; (partof,7005),!:_,i,,:_,:,-..'' : ' " •3 -- '..... ,, Pump:Suction(Part'ohTo05). _ • When one or more of the transmission oil cooler4 _ .;::,,.:..,, -Rele.ase:High_Appl_/,::_._,:; steel oil cooler tubes must be, replaced; each

(Part of 7005) replacement tube must be fabricated from the same

5 _ Forward Clutch Cylinder size steel tubing as the original,oil cooler tube.

Apply (Part of 7005) • Using the old oil cooler tube as a guide, bend the6.... Torque Converter Charge new tube as required. Add the necessary fittings, "

(Part of 7005) and install the tube.7 _ Pump Discharge

(Part of 7005) • After the fittings have been tightened, add oil as

8 _ Reverse Clutch Apply : , , needed, and check for leaks.(Part of 7005) Main Control Valve Body.

9 Control Pressure Governor(Part of 7005) Removal

10 Governor Pressure Output 1. Raise the vehicle on a hoist and position safety(Part of 7005) stands under vehicle.

11 Exhaust (Part of 7005) 2. Place a drain panunder the transmission and12 Throttle Pressure Valve loosen the bolts holding the transmission oil pan

(Part of 7005) to drain the oil from the transmission.13 Line Pressure (Part of 7005) ....14 _ Throttle Valve Pressure

(Part of 7005)

1994 EconolinelF-150,F-250, F-350/Bronco/F-Super DutyPowertr,,in/ Orivelr-inAug 1993

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07-018-28 Transmllslon, Automatic, C6 07-01B-28I II II I

IN-VEHICLE SERVICE(Continued) "_ " _ - ;. 1 - r . .

• - : / 3-.,-.-,Removethe attaching,bolts, the tr,ansmissionoil : • . 2: Rem_ovethebolts_,thatsecbre'.therear,engirie''.. ,._'_:.... i_., iI ,_: _i;_i,,f ilL I; ' .,';p_tnandoil pan to case gasket._.Remove:and ' support to the'transmission'extensionrear. ' ,:,

!';/" l: .-" _ diScard'the nylon'shipping'pluc_fromthe " " " support and insulator assembly to the , ::i_i!_i; Ii' .'_- transmission oil pan. This plug is used to retain crossmember. Refer to the illustration thatV_::_ I : _ transmission oil w thin the transmission during accompanies the transmission removal and _", | '. shipment and should be discarded when the installation procedure for the vehicle being '_'

; transmission oil pan is removed. • serviced."-_ /: ,:4. Remove_:themaincontrol valvebOdy'attaching 3. Remove the two crossmember-to-frame ,_.',- l _ bolts and,remove the main control valve body attaching bolts, and the bolts attaching the rear ,_

i_ " I ' from the_case, engine support brackets to the crossmember if

/' ;Installation i_' so equipped.'_i'i,"!:_,|_, ,_1. Position,_he main control valve body to the case 4. Using Rotunda High Lift Transmission Jack "'

:_", /"i_' making _ure that the gear selector valve rod 077-00019 or equivalent raise the transmission "; ._+_i;i_;_,,._// _ assembl_"and downsh ft detent inner lever high enough to remove the weightfrom the. ":_?_,_,,: _ . crossmember and remove theic:rossmember., ; ' ",i_.;_.-; ./_,.;_;;; .assembly are engaged: Install.and t ghten, the, , _2,_,-_;/L "1,_,'_;:.• attaching boltsto 11,14 N.m (95:125 in-lb). 5. Disconnect the muffler inlet p_pefrom the exhaust.... I!I_NOTE:,Do not grind or sand surfaces. Use a gasket manifolds and allow the pipe to hang.

,..scraper or wir.,ebrush to clean old gasket.material ' 6. Place a drain pan under the s;ervocover: Re_ove_from transmission oil pan and transmission gasket the bolts that attach the servo cover and_surfaces. _ identification tag to the transmission case.

2. Clean the;transmission oil pan and oil pan to case NOTE: Screwing in the intermediate band adjustment ..,,,"•: gasket surfaces thoroughly, screw as or before the intermediate piston and rod

" assembly is removed places tension on the _:3. Using a new oil pan to case gasket, install intermediate band. This will keep the struts properly

, .,. attaching bolts securing the transmission oil pan engaged in the band notches while the piston is,, to the transmission case. "tighten the attaching removed.

; bolts to 11-16 N.m (8-12 ft-lb).•_. 7. Remove the intermediate'band servo cover. "

'_. Remove;safety stands and lower the vehicle and piston and rod assembly and the cover gasket._. fill the transmission to the correct level with the from the case.

_... ,.,,.,,.specifiedoil..Refer.to,,rSpec.ificatiens_in_this"_L" section for proper capacity. B. Apply air pressure to the port in the servo cover,

if necessary, to remove the intermediate band ,_servo piston and rod assembly.

PA_qKI_'IGP;_WL FLUID 9. Replace the complete intermediate band servoAcruAr[_C,ROD SCR_E_ piston (7D021) and rod assembly if the

intermediate band-servo piston, piston shaft or ..... ""_--_L_--=_l "_.= h'_TERt'AEO_ATE piston sealing lips are damaged.,K'._---__OCEZEZZZ:E30_'2,,_ SERVOBANO " " .'

C..... CI t_ j_Y _,_ ,- _'_'/' LEVER 10. fromRem°vethe servo piston cover seal (7D026)'thecover.

:1. Dip.the new servo piston cover_seal in" ':transmission oiL .<_-;'

2. _nstallthe new servo piston cover seal on the :

__ _ !' °__i___'--' 1 cover.

- © I" _3. Coat new gasket with petroleum jell_,,and :1 • " ,," ' position on the servo cover.

4. Dip the intermediate band servo piston in

_! _ ____ o transmissionoil.Motorcraft MERCON,,Multi-Purpose Automatic Transmission Fluid"< oc ._'-_o_ ,o_ ,oc XT.2-QDXor-DDXE4AZ-19582-Borequivalent

MAINCONTROL/ and install it in the servo cover.VALVE BODY 1:)9291-8

5. Position the servo piston spring (70028) on thepiston rod.

Intermediate Servo

.,Removal

1. Raise the vehicle on a hoistand positionsafety 'stands under vehicle.

,:;% 1994 Econoline/F- 150, F-250. F.350/Bronco/F-Super Duty Power'train/Ddvetrain Aug 1993

Page 545: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B,29 Transmllslon,'Automatlc, C6 .. ,, 07-01B-29 '-- I I

,'. : IN:VEHICLE, SERVICE(Continued)... , ,

,_':.i,",, " I _6:,-:-, Insert, theintermediate band servo:piston'and.-:,: . - 2. Remove thethrottle valve controldiaphragm " ..:.i:.,'_:. _,"";'1: _,_,_i:i,:!_covet:in,,th_,case:ahdSecd;'e the'cover tO the,:_ _.... " retaining bracketbolt_ heat shield and_bracket.; :"i ,! ,. i_., 'casewiththe_attachingbolts,taking care toback Do notpryor bend.the.retainer clip; Pull the

,off the adjusting screw (7A178) as the cover • throttle valve control diaphragmfrom the case.bolts are tightened to 19,27 N.m ( 14-20 ft:lb) ....

,, • Make sure that theservice identification _ " ' _, • HEAT " RET_,INING'. _ . ._ SHIELO . ,BOLT. _'

tag Is In place. I. _ h i i ._I OIAPHR,_M,7,.: .Connect the muffler inlet pipe totheexhaust 'l P . , / ---_ }= I "_ _ I I RETAINER

8: Raise the transmission high enough to install the tll:_ _ j

crossmember. Secure the crossmember to the

rear'engine supp°rt:(6A023) with'the attaching __/_ _,__"

:, .... be Is: Lower the,tr:ansmission,,as-reqLlir, ed:-to: :_,:!. ""_.' l: i , _" :_q'_j_ q[ "_;: :1 '_ '}I "

] ; install !he crossmember,:tO::frame and rear engine::,. l l' " ' q l I supportlbiackets attaching bolts: Tighten the ,: l" "

9 Remove the jack from the transmission Adjustthe intermediate band as detailed in the

_ Adjustments portion of this section. ; OIAPHRAGM ASSEMBLY

10 Remove safety stands and lower the vehicle and ":7A377 O_tSFreplenish the fluid asoutlined in this section. .... ...... " :

,. 3 Remove the throttle valve control diaphragm from

• Installation

__ "_t 1., Install thethrottlevalvecontroldiaphragmin" : : I ' : ' ] " _ _ l I '12:' PUShlthe thf'0tfie_valvo_c,ont.ro!:diaphragm into the:': !!_

"case and position retaining bracket Install heat_, shield and tighten the bolt to 16-22 N.m ( 12-16

f{',/ill _ ft-lb)

__S (_ L.,_ ,,,_ 3. Install the vacuum hose to the diaphragm.06465-C

Extension Housing Bushingand Rear Seal

I Part ' SPECIAL SERVICE TOOL(S) REQUIRED

Item Number .- Description:;, -.. " " ,' . . De=crlptlon ToolNumber• 1 " ' "7005 :' : I Case : .... ' l ' ......... ' q ' _ , l I

2 70028 Serve Piston;Spring , Impact Slide Hammerl TSOT. t00-A

3 7D021 Intermediate Band Serve Seal Remover TOOL-1175-ACPiston ExtensionHou3ingBu_hlngRemover T77L.7697-D

4 .70026 ,, Servo Piston Cover Gasket ExtensionHousingBushingReplacer T77L.7697-Cl5l .70027 Intermediate Band Servo ExtensionHousingSealReplacer T6tL-7657-BCover

6 70024 Servo Piston Large Seal Removal

7 Identification Tag . 1. Raise the vehicle and position safety stands

'._ 8 57633-$2 Bolt (_4R eq'd)'. . ,. " - '_under vehicle. Disconnect the driveshaft (4602) "...... at the transmission.•

Vacuum Diaphragm

Removal

1. Disconnect the hose from the throttle valve•control diaphragm.

1994 Econoline I F- 150, F-250. F-350 / Bronco / F.Sup at Duly Powartrain / Driv attain Aug 1993

Page 546: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-30 Transmlnlon, Automatic, C6 07-01B-30I

| ,.

_. IN-VEHICLE-SERVICE(Continued). _ ._,,

2. .Whenonly,the rear seal needs replacing," + 4. Installthe sealinto the extensionhousingusing",/ ' ..... _" ,i+, ,;_ _ _-, _ca_'efully.remov.e'.itWith;a?tapered _hisel 0rlmpact",:. Extensior;HOusingSeal Replacer,T61L-7657.B., : ': ,._

; _,:,: _,i ,+SlideHammerT5OT- tOO-A and'Seal Remover " The seal shouldbe firmlyseated inthe bore. Coat

i" '- housingbushing(7A034). use Extension Housing PremiumLong-LifeGrease XGo1-Cor -K .....

,; BushingRemover T77L-7697-D after removing (ESA-M 1C75-B)or an equivatentlubricant. .,_ the rear seal. Use the extension housing

,+o:_, bushing4;emover carefullyso that thespllneEXTENSION HOUSING

:.... seal Is not damaged. _ SEALREPLACER ++,

i++,: ..)'_ _ -- .,.++.+_

;\i ".C S_AL_E_OVE. " ..

.+'+++++.. ' +:+++

:_+' 5, Coat the front universal ioint splinewith Premium•i _,,'ACTSuOE Long-Life Grease XG-1-C or -K (ESA-M IC75-B),AM_._ER.TSar+_o¢.,=,+.D_.tA or an equivalent lubricant and install the

:.... driveshaft.

_._, EXTENSIONHOUSING 6. Remove safety stands and lower vehicle.

__BUSHING REMOVER ."

._ T-/TL-7697-D

Extension Housing

Removal

1. Raise the vehicleon a hoistand positionsafetystands undervehicle.

2. Disconnectthe driveshaft from the rear axleflange and remove it from the transmission. On4x4 vehicles, remove the transfer case. Refer to _:

EXTENSIONHOUSINGBUSHING Sections 07-07A and 07-07B."tA034 D6.,tB'/,B '

3. Remove the rear engine supportand insulatorInstallation .. assembly-to-extension housingattaching bolts.

--1. ..... Wh_h i fiStalling_ tie-w-extension h0using bushing " 4. Place Rotunda Transmission Jack 077-000 i9 or .... ++use Extension Housing Bush+ngReplacer equivalent under the transmission and raise it justT77L-76"97-C. enough to remove the weight from the rear engine

support.

5_ Remove the bolts that secure t_e'_rearenginesupport to the crossmember a_remove the rear _' ',+

EXTENSION HOUSING engine support.

BUSHINGREPLACER 6. Place a drain pan under the rearof the

transmission case. ,

_,7. Lower the transmission and r.emovethe' extension housing attachingbolts. Slide the

extension housing off the output shaft (7060) andallow the oil to drain. +,

EXTENSION HOUSING _ InstallationBUSHING

7A034 CAUTION: Do not use a die grinder or similar tool ,ito clean gasket surfaces.

D64.M-B1. Clean themountingsurfaceonthe transmission

2. Before installinga new seal, inspect the sealing case andonthe extensionhousing.Positionasurfaceof the universal jointyoke for scores. If new extensionhousinggasket (7086) onthe

,. scores are found,replace the yoke, transmissioncase.

3. i .Inspect the counterbore of the extension housing 2. Hold the extensionhousinginplace andsecureit,, ._,:for,burrs. Remove burrs with crocus cloth ;, with the attaching bolts. Tightenbolts to 34-47 " "'

..... N.m (25-35 ft-lb). ++v

!! 1 gg 4 Econoline / F. 150, F-250, F.350 / Bronco / F-Super Duty Powertra in / Drivetr,,in Aug t 993

Page 547: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-0 IB-31 Transmlsslon, Automatlc, C6 07-01B-31" II

IN,VEHICLE SERVICE(Contlnued)

"":" "_:, ..:::,3:":,_.Raise"the,transmissior_.,highenough to position _.'. _.... NOTE: .Itis:recommended, thar this procedure be _' ,. ;'_ "' '_:1! .::':/.'' "_the_rear;engine Su'pp6rt onthe crossmembet.. ..... •';_"' " prior to'other:operationslto allow sufficient

ii; . 4..:,iSecure 'the supportto the crossm'ember with the .time for the.torque converter to drain properly.I "attaching bolts and nuts. lqghten the bolts to . 6. Remove the transmission h'ousing.cover from the

" I: ': specification.as listed;aHhe end of. this section.. .:. lower end of4he convert'er housing (7976). ,/. 5.._ Lower.the transmission and remove the jack. 7... R0tate the:torqueconverter until.4hedrain.plug " :,,;'"/ . . ' _lnstall the engine rear support-to-extension . . .comes into view...

" 1. " , •housing attachingbolts.,lqghten:boltsto -., -, . , "Ii"i ' :i:specific'atiohaslisted,at the.endof this section.' '- 8. Remove.thedrainplugandallow;the.transmissionI' . '-.On 4x'4 vehicles, install.the,transfer case. Refer : oil to drain..

/ " to Se'ctions 07-07A and 07-078. ,re. :,Flush'the_oil;cooler._t(_beslcompieiely asI 6., , Install the drive shaft: Remove safety stands and . , ,described:inthis_section. . . ;'.

I!'" ";:t°wer;the'vehic!e;t0-'!hefl0br;!'i II'' -'" +r$ " ` L" " "' _" ; . " " ': .... _'_'k'' '=i,_'CAUTlON:;Useo_an_oil!Otherthanspecified could•. ' 1"*!,:7.":<Eill_4he:transmission_;tb..thecorr_ectlevelWith'ihe;'.:.. : '.resu!t intransmission malfunction,and/or failute_

L Specified oil. . - :" NOTE One quart of transmission oil must be added to.......... torque converter BEFORE installation into the

transmission.

. 10.' .To.refill install, new oil_screenand,place a new oil

.... '. Transmission'Oil Drainand Refill • '. ' '.,,pamto, casebasket, bnTthetransmission oil pan,i Normal maintenance and lubrication.requirements do ,and.installithe.transmission 0illpan:on'the

not necessitate.periodic:automatic transmission oil' .':transmission6T_ghtenthe bolts4d 41-16 N;m,changes. .(8-12 ft-lb).

11'. Removesafety:standsandlower vehicle.:If a major, repair, such as a clutch band,bearing,. etc.;Is required: tnthe,transmisslon,Jt,wlll, have to. ,_' ,.12._Add'-4:%liters (5 qua_ts)!ofoil.for 4x2be'removed.for.'servlce.,At this time,the torque . .'. .. : .,-transmission oikpah0r_51.6liters(6quarts)'for

_.converter;.,transmlssi0n ollcoolers.andoll cooler.,. • " " ". 4X4_transmis._ion'oil"pah tothetransmissiontubesmust'b'e4.hor'oughlyback-flushed,to.- ..... • .. ..-th('ough;the;oil fil!e_',tube.. " ..remove any dirt.' Refer to procedure In this 13. C;qeck-theOil level. ' ,_,_ 'section. . , 'When used under continuous or severe •conditions, the transmission andthe torque ' REMOVALconverter should be drained and refilled with thespecified oil at intervals directed in themaintenance or owner's manual. Transmission, F-150-250-350, 4x2 and 4x4

Refer to the Truck Performance Specifications Book 1. Drive the vehicle onto a hoist, but do not raise ator the end of this section for oil requirements, this time. Disconnect the battery ground cable.

Disconnect the park/neutral position switch wireNOTE: Oil level indicator should be used to determine at the plug connector.actual oil requirements. Check,oil level when the _.....transmission is at n0f"ma[op_ratilnglit_mi_erat_rei Do_:_:_: 2. .Raise the vehicle on a hoist and position safetynot overfill. ' " , -" . .......... stands under,vehicle.

Procedures for partialdrain, due-to in-vehicle"repair , ' 3. Drain the transmission. Refer to Transmission Oiloperation, are as follows: :' Drain and Refill in this section.

1.. Raise the vehicle.on a hoist and position safety 4. Remove the convertor housing cover accessstands under Vehicle. from the lower endof the converter housing.

2. Place a drain pan under the transmission. 5. Remove the converter-to-flywheel attaching nuts.Place a wrench on the crankshaft pulley

• ' 3. Loosen the transmission oil pan attaching botts attaching bolt to turn the torque converter to gainand.drain the oil from the transmission, access to the attaching nuts.

. .. . .: 4. When oil has drainedto the,level of the pan 6. ' Drain the transmission. Refer to Transmission Oilflange, remove rest of the transmission oil pan Drain and Refill in this section.bolts working from the rear and both sides of thetransmission oil pan to allow it.to drop and drain 7, On 4x2applications , disconnect the driveshaftslowly, fromtherearaxleandslideshaftrearward from

the transmission, install a seal installation tool, or5. When oil has drained from the transmission, suitable plug, in the extension housing to prevent

remove and thoroughly clean the transmission oil oil leakage.pan. Discard the oil pan to case basket and thescreen. 8. Disconnect the d0wnshift and manuallinkage ......._'-

rods or cable controls from the levers at the.Ifit is necessary to perform a complete drain and refill, transmission. Disconnect park/neutral positionit will be necessary to remove the residual oil from the switch electrical connector,torque converter and the oil cooler tubes.

1994Econoline/F.150.F.250,F-3501Bronco,'F.SupetDutyPowerttainlDrivetre.inAug1993

Page 548: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-32 Transmlsalon, Automatic, C6 07.018-32II I I II_ II

._..

':!REMOVAL (Continued). , , -i_ . . •

9 Disconnecttheoil cooler_tubes from the° " ,., 10. With the wrench on thecrankshaft pulley;,, :. ! iI' , ,' tr,ansmission.'..'. ..... ' " ".. '" _ " attaching bolt, tur.n'thetorqueconverterto_gain " ' ..' _

•10 Remove the vacuum hose from the throttle valve access to the converter drain plug.Place a drain ,:'"_ cont'ol diaohragm. Remove the vacuum linefrom pan under the torque converter to containthe oil. .,' _._ the vacuum tube retainers. Then, remove the plug.With oil drained, re-install. . -'_i

•\ the plug. 'i_11. Disconne(:t thebattery to starier relay cable from

'! i_. :_the'termi_'aton the starter motor: Rem0ve, th_e" 11. Disconnect the driveshaft from the rear axle; _' three attaching bolts and remove the starter flange and remove from the transmission.To....' motor. _" maintain initial output shaft balance, mark the rear _", , .._; output shaft yoke and companion flange so they ,-:•,,_1,2,On F-Setiffs 4x4 and Bronco vehicles, remove the may be installed in their original positions._, tr:_nz,for _!as_. Refer to Sections 07-07A and .......

,_: 07.07B._! I 12. Remove transmission oil filler tube. . _ r J_ .

',!,13.Remove!the two engine rear,support and insulator 13. Disconnect the battery to start_,ir_relaycable at . ' ".... the starter motor. Remove the;i:_:-,,!,,._; assembly:bolts and position an appropriate, starter-to-converter'housing,'ati_;ching bolis and _ - ":,i_!_" engine support bar to the frame and engineoil pan

:_"i! flanges, remove the starter motor. ':_'_:•":_ 4. Remove the two engine rear support and insulator 14. Position an appropriate engine support bar,to the' frame and engine oil pan flanges. '"assembly;to-extension housing attaching bolts•

.i_15. Removeli_e six bolts securing the No. 2 15, Disconnect the oil cooler tubes from the

...., crossme_ber to the frame side rails, transmission. Disconnect the vacuum line from'_ " the throttle valve control diaphragm.,Remove the

'.:'!_.i6. Raise th_iransmission with Rotunda vacuum line from the vacuum diaphragm clip'_._ Transmission Jack 077-00019 or equivalent and (7F006) at the transmission..

: ,. remove the crossmember. 16. Disconnect the downshift and manual linkage_,i,7. Secure the transmission to the jack with the rods or cable controls from the levers at the

, ,,: safety chain, transmission. Disconnect part / neutra_position. .18. '-_Remove the transmission case-to-engine switch electrical connector...,, attaching_bo!ts. 17. Position Rotunda Transmission Jack 077-00019_,19._Move' the:transm=ssJon_away,,from'tl_e,'engme, or equivalent to support the transmission. Install' Hold torque convertor to transmission• Lower the the safety chain to hold the transmission.

jack. Remove the torque converter and i 8. Remove the nuts securing the rear engine support _transmission assembly from under the vehicle, and rear engine support insulator (6068)

assembly to the crossmember. Remove the sixbolts retaining the crossmember to the frame side

......................................... _ - - rails and remove the two rear engine support - -Transmission, E-150-250-350 brackets (6096). Raise the transmission with the

1. Disconnec;t the battery ground cable, jack and remove the crossmember.

2. Working from inside the vehicle, remove the 19. Remove the converter housing-to-engineattaching bolts. Hold torque converter toengine compartment cover, transmission. Lower the jack..R,_'mo_ethe torque",_,

3. Disconnect the park / neutral position switch ' " _" _' :converter and transmmsssonassembly from underelectrical connector, the vehicle. -_/-,,

4. If the vehicle is equipped with a V-8 engine. L "remove the engine air cleaner hot air tube.

5. Remove the bolt securing the oil filler tube to the iGovernorengine. .,

6. Raise the vehicle on a hoist and position safety Removal and Installationstands under vehicle. 1. Remove the extension housing as outlined in this

7. Drain the transmission. Refer to Transmission Oil section. ;,!Drain and Refill in this section, 2. Remove the four attaching bolts.

8. Remove the converter housing access cover 3. Remove the governor from the governor oilfrom the lower end of the converter housing, collector body flange.

9. Remove the converter-to-flywheel attaching nuts.Place a wrench on the crankshaft pulleyattaching bolt to turn the torque converter to gainaccess to the nuts•

- .._. 1994 Econollnel F- 150. F-250. F-350/B;onco/F-Super Duty Po_qertrain _Orivetrain Aug 1993

Page 549: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-33 Transmlnlon, Automatic, C6 07'01B-33 _' I I

' ' _ "r'_'REMOVAL (Continued) _ "

!"i :i_:.ii:''_. ; ,%,4_.:;"Refer't0,the, Disassembly and.Assembly.of,_ - ,.. , ,.e Handle-alltransmissionparts carefully toavoid ., :,- .,.' ';" " ':°;' ' I .:.,_."';_-:";Sdba._semiDliesportion;ofthis section.for:: : :...... nicking or_burringthebearing or mating surfaces.

governor,repair operations, ' Lubricate all.intemalparts of the_transmission withTo,install, reverse removal procedures. Tighten the ' , clean automatic transmission oil before assembly.

._. -; ._ :governor to governor, oil collector body fange bo tsto.,,. .e. Do not,use any other lubricants,except ongaskets •,. 1.1-:13N..m(97-115 in-lb).. • :and thrustl,rwashers_These may:be coated with. , ,

petroleumjellyt0.fac(iffate assembly;Alwa_,suse' " "new gaskets,and sealswhen assembling a

".. _. ,,., transmission.Refer!tothe Cleaning and Inspection': portion ofthssecton. , ., ..,

• :e _ghtenalibOItsand:,screws,,torec'ommended, .?tor,que._.Refe_.toSpecificat onsat end ofthis

O_L ., -section: . 1_',_:! ,;-,_ . -" :; .,,

' 'r "_'U 8E S ' r ; ;" " ' q' " " NOTE:If equipped, removeand discard the nylon '

.shipping plug from the transmission oilpan. This plug isusedto retain transmission oil within,the transmission

'during shipping..It should be discarded when thetransmission oil'pan is removed.

.' ,,1.' Removei.the!torque:converter;_ar_dmount the.,, , ,,,, ,._::'._transmission. n_hoding fixture.Rotunda Model..... ' ,. .:Ot4,0OlO6or,,equivalent_ , _ 'G0V_RNOA " ' "

OUTPUT_, SHAFT

. 7060

GOVERNOR OILCOLLECTOR.i]OOY,

70220 06.470-8

DISASSEMBLY

Transmission o_SPECIALSER;VICE"EooL(S)REQUIRED:.',,'i, .i ___i

Description Tool Number .....

Dial Indicator with Bracketry TOOL-420 1 .C 06471-8

Extension Housing Seal Replacer T6 tL-7657-B

AirNozzleAssembly TOOL-7OOO-DE 2. Remove the 17 oil pan attaching bolts. Removethe transmissionoilpanand oil panto case

Before removing any of the subassemblies, thoroughly gasket.clean the outside of the transmission to prevent dirtfrom entering the mechanical parts.

, NOTE: Duringthe repair of the subassemblies, certain ..... ,general instructionswhich apply to all unitsof thetransmissionmust be followed. Followingtheseinstructionswill avoid unnecessary repetition. •

1994 Econoline I F. 150. F-250. ,F-350 / Bronco / F.Super Duty Powertr ain / Orivetr=in Aug 1993.

Page 550: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-34 Ttanemltelon , Automatic, C6 : 07-0 IB-34; _ II I

, ;.-DISASSEMBLY(Continued) "/ "

...._,,>: v;: i

3. _Remove,the eighLmaincontrolvalve.body, >, :. ': "-.,." .... • .:i " " :'_

• ._;attachingf_omthe case,b°lts"Liftthe:.maincontrol:valve body. "

PAR Kli%G' PA'/V L FLUIO

,XCTUATI_;G RO0 SCREEN _ ::. ,

, i O

: FRO_TOIL

PUMP ASSEMBLY

-'-'_0 _ 0 _ '_0MAI_I COt'l TR.OLVALVE BOOY 09291.B

. Attach ffDial Indicator with Bracketry' ", TOOL-4:201-C to the front pump support .... ;._

(7A 108}_ Install Extension Housing Seal Replacer

. .... T61k-_657_B in the extension ho0sirRj't_center O_ALthe output shaft.

TOOL.4201 C

5. Pry the gear train to the rear of the case and atthe same time, press the input shaft (70 17) O6472.Binward until it bottoms. Set the dial indicator toread zero. 7. Remove the throttle valve control diaphragm,

....... throttle control valve rod and t,he primary throttle-NOTE: TransmisSion-e-nd playshould be within " valve from the bore in the rear of the case, Slip0.203-1.117ram (0.008-0.044 inch), the input shaft out of the front pump.

6. Pry the gear train forward, and note the amount

of gear train end play on the dial indicator. Record _.#:_the end play to facilitate assembling the _i;', ,.transmission. Remove the dial indicator from the ,._o._,:pump and the tool from the extension housing. .:_

:r.

;:)_ 1994 Econoline I F- 150, F-250, F-350 / Bronco / F. S up er Outy Powe_lrlin / Driv errs, in Aug 1993

Page 551: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-35 Transmltelon, Automatic, C6 07-01B-35Ill III IIII I ,i

•.' _?DiSASSEMBLY(Continued)__ - , '

:::8: ; Remove the.front-pumpettachingloolts.'Pw the_:'_ OUTPUT' ..... ';:_":._ _;._geartrain',forwardtoremove the pump.; ..... "'_' ' q ' IN'I'ERMEDIATE '' " SHAFT

_ " " = RRAKE DRUM 7060"/00_ , _ _ /

SHELL \

064?5-8

PUMPASSEMBLY'\ _ \_7A_03 .12. ,Remove.the bolts that attach the intermediateo_4z3.8 " bandiservo cover,to the case,

9.' _,_.1oosen the band adjusting screw and _remoVe the ,13;_,,Remove_the,cover;_intermediateband serve': - . -piston. !ntermedi.ate band servo,piston.,piston

. two struts. , . • spr, ing,andlgasket,f_om the case. - .of 10.,.,Rotate theintermediate'bandgOdegrees :'" ' _ ...... " " " '" ' "

-," -$4 : Rem0ye, the large,retaining.r ng thatlsecures the.._....:._,n,.counterclockwise:to.align the-end,_ with the slorin, . _,_- reverse.planet,cart er assemb y.',n;'theYeverse,._i_!E_,_

..... " ,; '_thecase.,Slidethe intermediate brakebandoff " ', clutch hub, Lift the thrust washers and reverse

' . the intermediate brake drum assembly, planet carrier from the reverse, clutch hubassembly.

--HIT- /_'_o _..._° o-_------_)_ "" 15. Remove the retaining ring that secures the output

_/,_O_, _ _ shaft ring gear and hub on the output shaft. Slide

the ring gear and hub off the output shaft.Remove the output shaft hub thrust bearing (9).

REVERSE

. CLUTCHHUB,, ASSEMBLY.7 BQ6T/:,...

8ANDENOS

SLOT

,, 1 1. Remove the forward part of the gear Vainas an " , /assembly.

OUTPUT SHAFT OUTPUT/ \ RETAINERRING GEAR AND SHAFT SNAP RING RINGHUB ASSEMBLY 7060 PLIERS

D7151.C

1994 Econoline/F. 150, F.250, F-350/Bronco/F-Super Duty PowertrainlDdvetrain Aug 1993

Page 552: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-36 Transmllalon, Automatic, C6 07-01B-36,- I I I Jl I III I Hi

• DISASSEMBLY AND ASSEMBLY OF.,, DISASSEMBLY(Continued).+ SUBASSEMBLIES" !- -.. i

16: Rotate4he reverse clutch hub ina clockwise.. " Main ControlValveBody;,. ,.''.' "

" _,direction and at:the same:timei, withdt;aw it from:" ' Disassembly '.the case.' CAUTION: Extreme care should be taken to avoid

-'.17, Remove!the reverse clutch retaining ring fromthe dropping, nicking or In any way damaging a valve,• case, then remove the clutch discs, plates and If a valve Is damaged or dropped, do not reuse It.". clutch pressure plate (7B066) from the case.

_i18. ,Remove :ihe extension housing attaching bolts NOTE: The oil pan screen or gasket should not be• reused• Use new screen and gasket when servicingfrom the.case• Remove the extension housing and the transmission. ,.,_extension.housing gasket• ..__- 1. Remove the ninescrews that attach the screen to

:19. Slide the;output shaft (with governor and ',,:-_, governo_il collector body (70220)) assembly the lower control valve body and remove screen• and gasket.,_ from the_tr,ansmission case.

Remove,the o_1dIstributor s eeve attaching bolts - :::;i, and remo_,_ethe oil distributor sleeve (7C232). O_LPANSCREENASSEMat.Y

LOWER CONTROL '_". output shaft parking gear and the output shaft-- " / ':','VALVEBOOY

_': ,

','" thrust washer (10). _'S('---_ ':_'/__t_

• If the output shaft thrust washer is staked inplace,,_u'se a sharp chisel and cut off the metalfrom b_hind the thrust washer. Be sure to clean

:;r the rea_rof the case with air pressure or asuitable solvent to remove any metal particles.

,-21• Remove the one-way clutch inner race attaching _ __! _ 3_

bolts fro_ the rear of the case. Remove the inneroverrunnihg clutch race and reverse clutch

": case.retainer_hdspringassemblyfr°minside°fthe_'_,i _o _ _ .__22. Remove:ihe clutch piston from the case using Air ..i'_

Nozzle A_sembly TOOL-7000,DE. 10z_.

AIR NOZZLE ASSEMBLY

\ TOOL-7000OE _-_0

10.24 x 1.5/8 INCH

..... REVERSE-

[_I(..)#_:_, _ _ CLUTCH OIL PAN SCREEN TO LOWER VALVEBODY AI-I'ACHtNG SCREWS

' PASSAGE 012528-A

D7153.B

• , :: 1994 Econoline / F- 150. F .250, F-350 / Bronco I F-Super Duty Power'train I Drivetrain Aug 1993

L ,.;,

Page 553: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-37 Trsnimlulon, Automatic, C6 07-01B-37I I I

DISASSEMBLY AND ASSEMBLY OF_"SUBASSEMBLIES(Continued)

LOWIER VALVE BODY "_

• o

.... 10:24'x;7/81NCH: _ ' _;,.... _ ,,

) ' '.'":;:', _ :,VALVE:BOOY ATr_CHINGSCREWS

' 2. ,,..;Remove,the iive upper.._to-lowermain;controlUPPER.TO,LOWER VALVE 'BODY AND' HOLD.OOWN PLATE ATTACHING ; ' ,_,valvebode/and,support platteattachingscrews.

.... , 'SCREWS ' _ . ,.._:Remove, thesevenlattachingscrews from theO12SZS:A ; : ,,_undersidebf the:lower control valve body. •

.... _3.,__Separate,the bodes, and_r,emove the,valve body'

........ _:'r ' . ' " " _separating,plate.(7A008)andvalve'bodyu ....

. Part ' ,:' :_ ' :;separats_plategaskeL Becarefuln0t tolose_

• ' .... Item. ;.Number .. Desci'iption . ' ' , _ , , . , ,

- - :., tl'te che,ck_valves and springs: Removeand _, :iI -- Screw. 10-24 x 5/.I 6 Inch clean the main control pump inlet screen if

(Part of 7A tOO) necessary.2 -- Screw. 10-24 x 5/8Inch'

(Part st 7A tOO) Main Control Assembly. 7AIOO3 -- Screw• t0-24 x 7/8Inch

(Part of 7A 100)

(Part of TA 100) _ *(_

5 -- Lower Control Valve Body

(Part of 7A 100)

6 -- Upper,:Control _/alve' Body ° •

(Part of7A100), (_5_ '

D12812.A

1994 Econoline/F.tSO. F.250. F-350/Bronco/F.Super (Duty Powertrein/Drivetrein Aug 1993

Page 554: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-38 Transmlltlon, Automatic, C6 07-01B-38I I I

!DISASSEMBLY ANDASSEMBLY OFSUBASSEMBLIES, (Continued) , ','

'7. Apply l'iar_dpressure on the pressure boost.valve, ' \Part sleeve end:and remove the;sleeve retaining'clip ."..... • _r'_

Item_" , ..Number .... .:,,Descrlptlon _ from the under side of the body. Slowly release " ._1 -- ShiftValvePlate hand pressure and remove the sleeve andthe

(part of7A100) pressure boost valve. Remove the two springs,2 7326 Geal SelectorValveRod the spring retainer and the main regulator valve ,._from the bore.3 -- DownshiftLever Stop.Inner

(Partof,7A100): 8. Apply finger pressure on the throttle boost valve4 -- ThrottlePressureBooster retaining plate and remove the two attaching

ValvePlate (Part of 7A100) screws. Slowly release the pressure and remove _:! 5 70227 SecondaryThrottle Pressure plate, throttle pressure boost valve and throttle

ValveSpacer Control Upper pressure booster valve spring, and the manualValve Body lOW2-1 scheduling valve and spring from the

; 6 -- ControlUpper ValveBody body. _.(Part of 7A100) ....

!. 7 ...... • LowerValve BodyPlate 9. Apply pressure on the remainingilshiftvalve.Reinforcement " reta ning plate and remove thei,e,ight attaching(Part of7A100) screws'• ' '

" 8 70100 Valve Body Separator Plate 10. Hold the valve body so that the p_ateis facingGasket upward. •Slowly release the pressure and remove

9 7A102' MainControlLowerValve the plate,_._ BodySuctionTube_ 11., Remove the spring and the intermediate servo,-_;_ (4 x 4 Only) modulator valve from the valve-body,.

10 7AO9B Oil PanScreen Assembly• '_':_ 12. Remove the intermediate servo accumulator• 1t 7E06,,2 Oil PanScreen Gasket" 12 -- ControlLower Valve Body vatve and springs.

(Part of 7A100) 13. Remove the 2-3 back-out valve and spring.

' 13 -- ControlValveBody 14. Remove the 2-3 shift valve, spring and the throttleSeparator PLate(Part o! 7A100) modulator valve end spring.

14 7E387 MainControlPump Inlet 15. Remove the 1-2 shift valve, DR-2 shift valve andScree_ .. the spring.

: 15 -- Shift ValvePlate 16. Remove the line pressure coasting regulatort f,Part o_7A_.00) valve.

NOTE: Refer to upper maincontrol valve body 17. Remove the cutback control valve to completeexploded view for locations in the following steps, the disassembly of the upper main control valve

4. Remove the manual lever shaft retaining pin from body. __ , . ...... the uppermain control'valVe body. "5. Slide the,manual shift valve out.

6, Cover the downshift valve bore with a finger, thenworking from the underside of the body removethe downshift valve retainer. Remove the springand downshift valve.

1994 Econoline/F-150, F-250 F-350/Bronco/F-Super Duty PowettrainlOrivetrain Aug 1993

Page 555: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-39 Transmleelon,Automatic, C6 07-01B-39il II I II i I

, ', DISASSEMBLYAND ASSEMBLY,. OF .....' _,,_SUBASSEMBLIES(Corttirtued_,

• ....... :i_:,i:,upper.Maln:ControlValweBody .........:., ';

D313$-E

Part PartItem Number Description Item Number Description

- 1 Shift Valve Plate 3 _ 2-3 Shift Valve(Part of 7A tO0} (Part of 7A100)

2 2-3 Shift Spring (7.3L Diesel 4 _ Throttle Modulating ValveOnly) (Part of 7A 100) Spring (Part of 7A 100)

(Continued) (Continued)

1994 Econotine / F- 150. F-250 F-350/Bron¢ o / F-Suoer Duty PnwArtrJ. I nt v*trAin Auo 1993

Page 556: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-40 Transmilslon, Automatic, C6 07-01B-40I|1 I II

DISASSEMBLYAND ASSEMBLY.OF _ "ISUBASSEMBLIES (Continued)_ ._,..

Pert " , Pert' '

iltem Number Description Item Number Description

5 ":_ 2-3 Backout Valve 22 -- Throttle Pressure Relief Ball,:;.. (Part of 7A 100) 1/ 4 inch Diameter ":_;

6 _: Inner Intermediate Servo (Part of 7A 100)

.. j.__ , Accumulator_Spring; 23 -- Spring Seat (Part of 7A 100)•_ (Part of 7A 100) 24 -- Boost Valve Spring

:'._.7 Outer Intermediate Serve (Part of 7A 100) ,_i_

,;_- .,..:_i; Accumulator Spring 25 -- Pressure Regulator Spring ";" ' =_

i; '_.. (Part of 7A 100) (Part of 7A 100)8 Intermediate Serve 26 Booster Valve

-:_, Accumulator Valve (Part of 7A_I00) _,_'_'_,_,. (Part of 7A 100) .;_.:: ÷_._, 27 Reta net (_a'rt of 7A 100)g Intermediate Serve _ ,_;

.... . Modulator Valve Spring " 28 Main Oil'P,;'essure Boost' (Part of 7A 100) Valve Slee_.... (Part. of 7A 100)

Intermediate Serve 29 Reverse Clutch Check BallModulator Valve (Part of 7A 100)

; :!i!_" (Part of 7A 100) 30 Main Regulator Valve2- 1 Scheduling Valve (Part of 7A 100)

, .;_, (Part of 7A tOO) 31 2-3 Shift Valve Check Ball12 .:_., 2.1 Scheduling Valve Spring (Part of 7A 100) .

_"; (Part of 7A 100) 32 -- Converter Pressure Relief

13 ' 'i! I Throttle Pressure Booster Valve (Part of 7A 100)_-. Valve Spring (Part of 7A 100) 33 -- Converter Pressure Relief

14 ':_ Throttle Pressure Boost Spring (Part of 7A 100):, Valve (Part of 7A 1OO) 34 -- Upper Valve Body

15 ':: (Part of 7A 100).._. Throttle Boost Plate: ":. (Part of 7A IOO) 35 -- 2-3 Backout Valve Spring "_";

,_ 16 7022Z_ , Throttle Pressure.,Valve (Part of 7A tOO) ......,r. Second.ary Spacer ' -- 36 -- Throttle Modulator Valve

17 Oownshift Valve Spring (Part of 7A tOO)(Part of 7A tO0) 37 -- Cutback Control Valve ,_._

18 Manual Shift Valve (Part of 7A 100) '_(Part of 7A 1OO) 38 -- Line Pressure Coast Valve

19 Throttle Downshift Valve (Part of 7A 100)...... (Par.tof7AtOO) 39 --. 1-2 Shift Valve Spring ....

20 Manual Valve Retaining Pin (Part of 7A 100)(Part of 7A 100) 40 DR-2 Shift Valve .

2 I Throttle Pressure Relief (Part of 7A 100)Spring (Part of 7A100) 41 1-2ShiftValve

(Continued) (Part of 7A.":]:OO).::.'_i_._"

_,.._

Assembly .2. Place the upper main control'valve body on a

1. Place the downshift valve and spring in the upper . ._.. clean surface with the passage'side facing up.. ,,, .main control valve body. Compress the spring .:" Place the converter relief valve spring in its bore.and install the retainer from the underside of the Coat the converter pressure relief valve withmain body, petroleum jelly and place it on top of the spring.

Place the 2-3 shift valve check ball in its cavity.

Place the throttle pressure relief valve spring in ';_its bore. Coat the throttle pressure relief valve :.,:?check ball with petroleum jelly and place it on top

,. of the spring. Place the reverse clutch check ballin its cavity. ,-_

19931994 EconolinelF.150 F-250 F.3501BroncolF.Super Duty Powertrain/Drivetrain Aug

Page 557: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-41 TransmlsMon, Autometlcl C6 .. 07-01B-41"|| I I II ;

_i• DISASSEMBLY AND"ASSEMBLY OF

',':-'. SUBASSEMBLIES (Continued) • .......i_....... . :"i

•/"" " 4. • Place,the lower maincontrol valve body,and" " ' , ,separating plate on the,upper rnain control valve

body and install theattaching screws finger tight,

5.. Installthe oil,screen sc:rewsloosely, without thescreen-to properly alignthe upper' and lowermain,control valve,bodies;-gasket a'nd'valveb0dyseparating plate.

6. ,,:'13ghten,the:two_boltsthata_e covered by the- ,'screen to 5-:,7N,m (44-62,in-lb). '

.7., • Remove,the oi scf'een attaching screws and .',. ,: p!ace,theoil:scr.een:and0il screen in position.on

.:,;the lower'main controlwalve;b0dy. Re-install the:: screen attaching.screws• .,

" ' ' 8. ;l_ghten-all themain control valve body and screenattaching screws.to 5-6 N,m (44-53 in-lb).

9. Place the cutback control valve and the line,, ,,:pr_essure,,coastingr.egulator,,valvein the main• :cont¢ol'valve body.

.... 10 _,-Pla(:ethespring DR:2 shift valve and the 1-2 shift: ' .... - . ,_,v,alve.in the maincontrol valve body. ' •.

< 11., ,Place thethrottle modulator valve and spring and. -__the2-,3shift,valve (aad spring on 7.3L diesel) in

:themaincontrol ,valvebody•

, 12. Placethe'spring:and the 2._3backout valve in theDTt54-C• _maincontrol valve body'•

1 - _' 13' ,. Place the'_two:,spfingsand the intse/mediateservd:.,,_,,' ' Part .... 1,accumulator valve.'in the"rfiaihcont?ol'va'lve 'body::"!"Ite'm , Number Description 14. Place the intermediate servo modulator valve and

1 -- Converter Pressure Relief spring in the main control valve body.Valve (Part of 7A 100) 15. Carefully place the valve retaining plate on the

2 -- Pressure Boost Valve main control valve body and secure it with theSleeve (Part of 7A 100) eight attaching screws. Tighten the two hex head

3 -- Converter Pressure Relief screws to 3-5 N.m (27-35 in-lb). "tighten theSpring (Part of 7A100) remaining six screws to 3-4 N.m (27-35 in-lb).

4 -- Downshift Valve and Spring(Part of 7A100) 16. Place the throttle pressure boost valve and

5 -- Throttle PressureRelief Ball throttle pressure booster valve spring in the main(1/.4.nchD amet er):an,d",.':-:..:, control valve body• Place the manual low 2-1

_Sp'rlng (Part of..TA100)/ " scheduling valve and spring in the main control6 _,,.........:. _ Downshift,Valv.eRetainer_-,_'-,, valve body and install the retaining plate• 13ghten "

(Part ot 7A'100)'; . the attaching screws to 3.0-5.0 N.m (27-44 in-lb).

7 Reverse Clutch Check Ball 17, Place the spring seat on the stem of the main( 1/ 4 inch Diameter) regulator valve so that the retainer flange is next(Part of 7A100) to the valve shoulder. Place the main regulator

8 -- 2-3 Check (Ball 1 / 4 inch valve, spring seat. two springs, pressure boostDiameter) (Part of 7A100) valve and sleeve in the bore• Apply hand pressure

3. ,Install the small main control pump inlet screen in on the end of the pressure boost valve sleeve and, the valve body separating plate if itwas _,. , ., install the,spring clip retainer in the groove on the ,

.. ..... :.... previously, removed•. Be sure the, transmission ,- under sideofthe body,so.that the.clip is inserted ,main control screen tabs are flush with the into the end groove in the sleeve. Be sure that thevalve body separating plate surface. Carefully pressure boost valve sleeve is free in its bore.position the separating plate and new gasket on 18. Place the manual valve in the main control valvethe lower main control valve body. Place the two body and install the retaining pin in the body. 'hold-down plates on the valve body separatingplate and install the attaching screws finger tight.

Page 558: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' II

, 07-01B-42 : Transmission, Automatic,C6• ..... " 07-01B-42 •• I I I I II

•__DISASSEMBLY ANDASSEMBLY OF-

., ..... Front, Oil PumpSo I..... 1.- . Remove frontoil pump seal using Slide Hammer' i 'i'i

2. Install front oil pump seal using Front Pump Seal

o..o.,o.o°I Replacer T89L-77837-AH. , :_'_

_,/'r'_"p'_'Slide Ha'rnn, lef ITsoT:,0o^" 'I liF,o.,"._oB.._i.g..p,._e, IT6eL-7003-C2 ".,._

_:!_::/ .: DIsassembly}_And,,.._ Assembly:: | 'NOTE: For edse of installation the front oil pump seal<:.. | ,can be replaced after the pump has been installed on,,_.,-_.,| ,, ,,the transm ss=on. ': _

:. | -" FRONT OIL• I ': PUMP'i,!., I ',: ASSEMBLY .,,_

,. i:' / " :_ '_;' _'__/_/_-._/_" / _ \\ HAMMER TOOL

.....I ,: /_._././"/_._" \\ TSOT-,OO.A

;i " FRONT PUMP _

SEAL REPLACER FRONT OIL1"8/L-77837 .AH PUMP

S ER

..... ......-I....-. 07t588

Front Oil Pump

Use the following illustration for component location •; " 'and orientation.

012813-1

"-_ 1994Econoline/ F- 150.F-250. F-350 / Bronco/F-SuperDutyPowertreinIOrivetrainA_g1993

Page 559: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-43 Transmission, Automatic, C6 07-01B-43 :iI

DISASSEMBLY AND ASSEMBLY. OF• :'SUBASSEMBLIES(Continued) - :

""_ " -_ :_' , _.,:. :, _,,_,_Part,_ . .... - _. ", ,.. ' Part"

• ,' Item Number.,"- Description, ' , 4: Item Number' .,'l Descrlptloni1' 7A248 FrontOilPumpSeal (Small) 6 PumpDriveGear2 58619-$2 Bolt(OilPumpto Converter. (Part.of 7A103)

, " .Housing)(7Rsq'd) .' : 7. 7A108 " ' Fr0ntPumpSupport•3. 7B258 . FrontOifPumpBushing ,, .."Assembly : '4 -- ' FrontPumpBodyAssemb(y 8 " '20346-$8 ' Bolt(PumpBodyToSupport)

• ' ' (Part of 7A103) '- : - (5 Req'd)5 PumpDrivenGear- .9': ; _-7D(_14': .. • , *",...ThrustWasher(No. 1)

.... (PartotTA103). 10_ .7A248 -.. Fron!.OjlPumpSeal(Large)'(Continued) . . _1.1.,,,.70025 " .... '.c..:, IntermedialeBrakeDrum

'" '" i ,Seals (2"Req'd)_': ' . i2_ 7A'136'":' _II'I:_I:' O,P,,m_Gasket

Disassembly

1. Remove the two front oil pump seals and the, selective,fit thrust washer (7D014) m No. 1.

- , '.,

•2.. Remove the.large square-cut seal from the: outside diameter of the front pump support and FRONtPUMP

gear housing• .BUSHINGREPLACER• ,, T66L-?O03-C2

3. Remove:the five.bolts that secure.the front pump• , body to,the,support assembly.

•.. ,4.: Remove the driveand the ddven gear from the

• housing. . .,. HANOL'__,.... . "! 'NOTE:. If the.front oil pump bushing (7.B258)is worn or

,., damaged, rep ace tus ngthe handle and Front Pump :": " ,,:',.Bushing Replacer T66L-7003-C2.

5. Place the new front oil pump'bushing in'position,making sure the half moon slot in the front oilpump bushing is on top and in line with the oil lubehole near the seal bore. Press the front oil pumpbushing in 1.52-2.03mm (0.060-0.080 inch)below the front face of the bushing bore. UseFront Pump Bushing Replacer T66L-7003-C2 andhandle to seat the front oil pump bushingproperly. After assembly, the half moon slot mustbe in past the,lube hole to:provideproper._::..:..'. _"lubrication.

D7161-IA

Assembly

1. Install the drive anddriven gears inthe pumphousing. Each gear has either anIdentification mark or chamfered teeth onone face. The Identification mark or the.chamfered surface on each gear must beInstalled toward the front oil pumpbushing/front oll pump seal end of thehousing.

2. Positionthe front pump supportand gear in thehousingandinstall the five attaching bolts."13ghtenbolts to 17-21 N.m (12-16 ft-lb).

1994EconollneIF. 150.F-250,F-350/Bronco/F.SuperDutyPowertrain/OrivetrainAug1993

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07-018-44 Tranemleilon, Automatic, C6 07-018-44• II I

DISASSEMBLY AND ASSEMBLY OFr " SUBASSEMBLIES"(Continued) : '

:_3:':Carefully_instalLtwo new frontoil,pump'seals on - .... 4, lnstallsection.theselectivethrustwesher: Make sure_: ' ii i "'"" " '.i:

' " thelfront.pump,suppor.LMake,sure_that the ends: ,. that the correct thicknessselective thrust :-"i" , ....

" of the fronLoil pump sealsare engaged to lock ..... washer is being used to obtain the specified.;-, them in piace. Install a new square-cut seal on the end play. Refer to Specifications at end of this '

outside diameter of the housing.

', .The front oil pump seal can be replaced after the front._, 5. Place the front pump support and gear on the_;. =pump support(and gear has been installedon the torque converter, making sure that the drive gear',-_ transmission u'sing Impact Slide Hammer T5OT- 100-A engages the torque converter hub. Rotate the

land Seal Rern'_ver TOOL- 1175-AC for removal, and front pump support and gear to make sure thatFront Pump Seal Replacer T87L-77837-AH for the gears rotate freely. i;_'

;i .installation.._i;i

;L ° :"

:Direct Clutc'_'i k_'

_'_Refer to the following illustration.for component ._;_i:'; ,:locahon and orientation.

2 '_

ili:i (

Dt2814.A

Part Part

Item Number Description Item Number Description _i

1 70044 Intermediate Brake Drum 7 377136-S Ring _ (Used as Direct .•Assembly Drive Clutc.h Piston Spring

2 7E056 Direct Clutch Piston Oil Seal Retainer)_'-_,Inner 8 78442 Direct Cl_.t_hExternal Spline

3 7A548 Direct Drive Clutch Piston Oil Plate (St_!_i.)Seal _ Outer 9 78164 Direct Clutch Internal Spline

4 7A262 Direct Clutch Piston Plate (Friction)Assembly I 10. 7B066 . Direct Drive Clutch Pressure ".

5 78488 Direct Drive Clutch Piston PlaleSpring ( 10Req'd) 11 70428 Intermediate Brake Drum

6 7A527 Direct Drive Clutch Piston Thrust Washer (No. 2)Spring Retainer 12 377126-128S Retaining Ring, Selective Fit

(Continued) 377437-377444- (7B066 in 7DO44) ' i:_

SPECIAL SERVICE TOOL(S) REQUIRED

OelcrlpUon Tool Number

ClutchSpringCompressor T65L-7Z515-AAir.NozzleAssembly TOOL-7OG0-DEClutchHousingBushingTool T69L-70044.B'.LII:)'Se_IProtector T77L.77548-A

• 1994 Econoline/F. 150.F-250, F-350 / Bronco/ F-Super DutyPowertrain/DrivetteinAug1993

Page 561: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-45 Transmission, Automatic, C6 : 07-01B-45-ml I II I

" DISASSEMBLY ANDASSEMBLY OF', •/.SUBASSEMBLIES:(Continued_ ..

....::!' : _ ,, _' ::=i'.:Dlsassembly,:i..",_: " _./i. . . " . _, • 4. Remove the retainingringand removetool., ,'

.:, ,1. • Separate thedrive trainl Remov.ethepressure , Remove theclutch piston'spdngfetainer (7A527)plate retaining ring. ' .,and thedirect Clutch pistonsprings (7B488) (10

required).

• ' . 5/ Piston facing,down app y air p('essure:to the , ,• ,clutchpiston,apply,holeinthecldtch drum using ..... "_

...... Air Nozzle AssemblyTOOL-7OOO:DEand removethepiston ....

AIR NOZZL'E

• ' E

.... _ , _ ' _ D7162-B

_2. :.Removethe.clutch pressure plate andthe clutchpack (internaland external spline).

,3. ' 'Install ClutchSpring CompressorT65L-77515-A• : on the intermediate.brake drum. Make•sure that,". the legs:clear theretaining ring,enough,to remove .oTt_=-_A

it. ,. ' 6:1-_Remove thb,dir,ect',Clutchpiston,outer:seal!from _ _:,, .. the_Clutchpistsh:and'the directclut(_h inner seal, r.

from the intermediate brake drum.CLUTCH

CLUTCH SPRING PISTON AssemblyCOMPRESSOR 7A262

T65L.77515,A I. Dip the new seals in transmission oil and installdirect clutch inner seat (7C099) on the

, intermediate brake drum and direct clutch pistonouter seal on the clutch piston.

2. Install the clutch piston in the intermediate brake

l drum._LU'_CHP!S_ON:_-,.,

_ 7AS27 _ ......DIRECT CLUTCHPISTON SPRING

78488

CLUTCHSPRINGCOMPRESSORT65L-77515-A

BRAKE DRUM

70044 07163-B

Page 562: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-46 Tren,mleelon,Autometl¢,C6 _ 07-01B-46I I I I III

,.= DISASSEMBLY.ANDASSEMBLY, OF .... ._-. • ".

SUBASSEMBLIES(Continued) #_ ....

3: _Pos t onthe direct clutch,piSto.nspr!ngsin-the_ ,, '" 6. After allclutch plateshave been installeU,__ ' : '" ,/_. ': clutch pistonsockets,'Place the clutch piston positionthe clutchpressure plateinthe ._,

,_ springretainer onthe direct clutch pistonsprings, intermediatebrake drum. Installtheclutchpressure plate (selective) retainingring.

7. With a feeler gauge, check theclearance"" DIRECT CLUTCH P1STON SPRINGS MUST BE between the clutch pressure plate and retaining• ,_ _ , ' INSTALLEO IN POCKETS MARKEO_X ONI_Y " '_': ring.

The clutch pressure plate shouldbe held ._i_8.._ downward as the clearance is checked. The _-"•, clearance should be 0.558-0.914ram

i_'i" _i (0.022-0.036 inch).,. i:_ _ • If the clearance isnot within_!_ecifications.,

::_ selectwe thickness reta_n_ng_r,!ngsare available;_"_ in the fo lowing thicknesses:J._i:"

"_' 1.42-1.52ram (0,056-0.060 i_ch)_" 1.65-1.75mm (0.065-0.069 inch)

1.87-1.98ram (0.074-0.078 inch), _,_ 2.10-2.20mm (0.083-0.087 inch)

2.33-2.43mm (0,092-0.096 inch)2.79-2.89mm (0.110-0.114 inch)3.25-3.35mm (0.128-0. 132inch)Install the correct sizeretaining ring and

10 DIRECT CLUTCH PISTO_ re-check the clearance......... SPPJNG OEStGN SHOV_N

•_.' 023,54-0

_CAUTION: Before releasing the pressure on the i":tool, make c_rtaln that the retaining ring Is

_,positioned Inside of the four reta!Qlng_,r.!clgguideson the clutch piston spring retainer.

4. Install Clutch Spring Compressor T65L-77515-A _iand compress the direct clutch piston springs.Make certain that the clutch piston spring retaineris centered while compressing the direct clutch

_ _ p!s!o.n spr!ngs: In_stallt_heretaining ring ..... " i i5. Clutch plate usage varies with each model. Refer

to the Specifications at end of this section for the•number of plates required. Dip the clutch plates inclean transmission oil. Install the clutch platesalternately starting with a steel drive external _"_"" _" _splined clutch plate. When new friction plates are _:;;:_'_ 'used, soak the plates inautomatic transmission Forward Clutch ,,,.=.:.oil, Motorcraft MERCON • Multi-Purpose Refer to the followingiltustrationfor componentAutomatic TransmissionFluid XT-2-QDX or -DDX Iocationand orientation.(E4AZ-19582-B) or equivalent for 15 minutes _;.,before they are assembled. , :

:_'; 1994 Econoline/F.150. F-250. F-350/Bronco/F-Suner Duty PowertrainlDrivattJin A,m tgq:3

Page 563: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B-47 Tranemlnlon, Automatic, C6 07-01B-47

• .DISASSEMBLYAND ASSEMBLY OF_' _":'SUBASSEMBEIES(Continued),_.

c=....... ' ;.Forward. utch_,,.".......•...:,. , . ,' ;.'

0 " "

4

D7169.C

Part Part

_ttem :Number.. _ Descriptlon ,Item '..;,Number !:, 'Description

11 .7'130t9 . ,, Forward.clutch cylin-der seal, .,., '=8".:.377127:S', ::. ;: ',, .Retaining,Ring., ' (2:Req'd) " 'r ,'9!.'_ .7BO66": .. !' ':%", .F,orwardClutch Front .

" '..2, 7A360 ' " Forward ClutchC_/lindei' " ' ,-, .:,."_"'::',,_..,,.,,_.,,.,:,'""Pressure Plate _ _:.:'.:,,,_,"j'_,i,_.':,;_;;3 _7A548 ' • • , Forward'Clutch PistOn Oil 10 _ '7E085:1' " ",_ l'orwaidClu't'chPressUre ......"'

Seal (Inner) Spring. 4.. :..7A548 Forward Clutch Piston Oil 11 7B164 For'ward Clutch Friction

Seal (Outer) " Plate (Internal Spline)5 . 7A262 Clutch Piston 12 7B442 Forward Clutch Steel Plate6 7D256 Forward Clutch Piston -(External Spline)

Spring Ring 13 7B066 Forward Clutch Rear7 7B070 Forward Clutch Piston Disc Pressure Plate

,r Spring 14 37T 127-S Retaining Ring. Selective Fit(Continued)

SPECIAL SERVI'CE_TOOE(;S)';REQUIRED;_:,_", _ ' ......

Description Tool Number

Clutch Spring Compressor T65L.77515-A

Air Nozzle Assembly TOOL-7OOO-DE

Lip Seal Protector T77L.77548*A

1994 Econoline I F- 150. F. 250, F.350 / Bronco / F-Sup et Duty Powertrain I.Drivetr,,in Aug 1993

Page 564: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-48 ' Transmlselon,Automatic,C6 07-01B-48I

DISASSEMBLY AND ASSEMBLY OF

;SUBASSEMBLIES.. (Continued),r i. ,_,.

Disassembly i , 5. Apply aif;,-pressureto.the forward Elutchcylindbr_ ! . • . ' : " '.-,1_._:_Remove the'clutch pressure;plate'retaining ring, ' . between:the 2 Teflon,seals usingAir NoZzle': ............. '/_. i-" ii"

Assembly TOOL-7OOO-DEto remove the clutchpiston.

AIR NOZZLE _ : :::RETAINING RING ASSEMBLY /_J- .,_.---------_

_!i TO

• _. O7168-n 6. Remove the forward clutch piston outer_sealfromthe clutch piston and the forward clutch inner seal

2.1;::,Remove the.,forward clutch pressure plate and from the forward clutch cylinder hub....._. clutch pack from the forward clutch cylinder.

31',i- Remove the forward clutch pressure spring and Assembly':' forward cl(itch front pressure plate: , 1. Dip two new seals in transmission oil, Motorcraft

• , , MERCON '_Multi-Purpose Automatic.4. Remove the retaining ring, p_ston disc spring and Transmission Fluid XT-2-QOX or -DI]X

piston spring ring using clutch spring compressor (E4AZ- 19582-B) or equivalent. Install the smaller ,_-!._T65L-77515-A.forward clutch inner seal on the forward clutch ,'_cylinder and the forward clutch piston large sealon the clutch piston.

- 2: Install the clutch piston with Lip Seal Protector _.T77L-77548-A. ,

FORWARD CI_U TCH'

PISI"ON SPRING • LIP SEAL

RJNG PqOrECTOR

70256 T71L./1548.A _ ,__._..

"_ ' ,,_.,,%_,. ': '._

;I)7171-1A

CLUTCH SPRING

COMPRESSORT65L-77515.A

" 071,70-8 !

;'_';',._., 1994 Econoline / F. 150. F-250, F -350 ,' Bronco / F.Supet Duty Powertrain / Dr [,,_etrain Aug 1993

Page 565: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-49 Transmission, Automatic, C6 07-01B'49 :,I II In II • I El I

• DISASSEMBLY AND ASSEMBLY OF:,SUBASSEMBLIES(C0ntinued) ' '

• ,, . , . • .

" -3., : P_ositi0nthe LipSeal_,Pfotector_T771L"-77548-A .........-with the,clutch'piston,into,the forward clutch,,.- ' , ".

" - ' ....cylinder,.so that the_bore of the:tool is aligned "•with'the clutch piston bore in the forward,clutch CHECKBET_NEENcylinde;'.Press the clutch piston into the forward /RETAINING RINGANDTE-TB06_

.... clutch cylinder until it.bottoms in the bore:Remove the Lip Seal Protector T77L-77548,A. " ' • ,

,4. Make sure that the forward clutch piston spring _.,_.... _..... 'ring is,inthegrooveon the piston. Position the j•. • , disc,springinthe forwardclutchlcyllnder ,

' .... ._;.'-with thedishedface, downward, lnstall the-, . spring so the clutch springring andspring are in •

.... ,, , ',contact. Secure.the disc spring with the'retainingring. " .

.' ,5 .,i,,,Install the,forward_clutch' front pressure:plate and!., _,_\,_-,A\_//_/,+:forward clutchpressure,spring:., " ,, _ '

NOTE:,New,frictionplates should be soaked in cleanMotorcraft Mercon Multi-Purpose Automatic,Transmission Fluid XT-2-ODX or DDX,(E4AZ-,49582-B) or equivalentprior to installation.6.,._ Install_theclutchpack ' starting witha steel plate o7172.c

., (external splined) alternating with friction'plate_,(internalsplined):.The number of plates.are model

dependent. Refer to.specification section for ..,• number of plates.

.7._ 'lnstall_the forward clutch pressure plate and ' .:, InputShell:and Sun;Gear., ,'retainingring:Making,certain.that the ring seats Disassembly " ' "

• fully.,in the groove.' •. . '_ .. 1......Remove:therea'i" retainiqg,i_ing.fr,6m,thesun gear.:'8. ' With afeeler gauge, checkthe cleai'ance.

, ,,between the retaining ring and the clutch _ aEAI_pressure plate. Downward pressure on the clutch . . _ _,_'7_"_ / RETAININGpressure plate should be maintained.when 'making this.check:Clearance should be "0.533- 1.168mm (0.02 I-0.046 inch).

9. If the clearance is not within specifications.selective retaining rings are available in thefoltowing thicknesses:1.42-1.52mm (0.056-0.060 inch). 1.65-1.75mm(0,065-0.069 inch), 1.87-1.98mm (0.074-0.078inch). 2.10-2.20mm (O.083_O,087Jnch)._......2 33-2 43mrn:(O:092_0_O96Jnch)_2,:79,2i89mm_.;-:.,(0.110-0.1 l'4'in_;h) add3.25-3i35mm'?,,. '_?, , ....(0.128-0.132:inch')_ Inseri/'th'e"c:o_r'rect_size`_'_':_'_'r_:'_'retaining ring and recheck the clearance.

SCREWDRIVER '_-_- ..J - ,• 07173-6

2. Remove theinput shell thrust washer,(7D066)from the input shell and sun gear.

3. Working from inside the input shell remove thesun gear. Remove the front retaining ring from the,

• ' sungear.

Assembly

1. Install the forward retaining ring on the forwardend (short end) of the sungear. Working frominside the input shell slide the sun gear andretaining ring into place making sure that thelonger end is at the rear.

1994 Econol no/F-150 F-250. F-350/Bronco/F-Super Outy Powertrain/Orivettain Aug 1993,

Page 566: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-50 Transmission, Automatic, C6 07-01B-50I J I I

- ' •ASSEMBLYOF ' '"DISASSEMBLY ANDSUBASSEMBLIES (Continued) _.•.: r"....

2, Ptlacetheinput shellthrustwasher-on the sun ' - " , - :i::i• _gear:and'installthe rear:',retainingring. "_'Rartl ,:

item Number Description4 70026 ServoPistonCoverGasket

FRONT1RETAINING RING INPUT SHELL 5 70027 Intermediate Band Servo

377"I00-S THRUST WASHER Cover " ':

/ SUNGEAR 70066 6 7D024 ServoPistonCover Large/ .70o63 /'- _ Seal

8 57633-$2 Bolt(4 Req'd) • ._, i:_:'_':_' Disassembly

1. Replace the intermediate bandservo pistonassembly if the intermediate band servo piston

• rod assembly or sealinglips are_.damaged.

REAR 2. Remove the servo piston cover_:gasketand servoINPUT RETAINING/ piston cover large seal from the cover.

'::'i/_, SHELL RING';' 70064 377300.S Assembly

"::/ :_i_ o7t74.c 1. Dip the new seals inclean transmissionoil..... _'_. 2. Instatlnew servo piston cover gasket and servo

"-'_ piston large seal on the cover. Coat the new

'/ [ "i- _ servo piston cover gasket with petroleum jelly. ,f: : Intermedlat .Servo necessary, to hold it in place, .

i• . J -,:Refer to the following illustration for component 3. Dip the intermediate band servo piston and rod:': t location and oi'ientation, assembly in transmission oil. Motorcraft

L MERCON= Multi-Purpose Automatic

i: 'i;'- ! i1!_., TransmissionFluid XT-2-QDX or-DDX' ,_,

ii.,i o', !!_ _0' -_.........._ _-._.. r_,,,'_ (E4AZ" 19582-B) or equivalent and install.it in the

_ii " - - piston cover.

!:o 4. Position the servo piston spring on theintermediate band servo piston rod.

5. Insert the intermediate band servo piston and rodassembly with cover in the case and secure thecover to the case with the attaching bolts, taking

, care toback of1 the band adjusting stop as the ............... intermediate band servo retainer bolts are

tightened to 19-27 N.m (14-20 ft-lb).

, , • Make sure that the service Identification

os_6s-c tag Is In place.

Part ....

Item Number Description Governor

1 7005 Case _Refer to the following illustration for,l.component .:"2 70028 Servo PistonSpring ;,location and orientation.3 70021 IntermediateBand Servo

Piston andRod Assembly(Continued)

)

".._. 1994Econoti.ne/F-150,F-250,F.350/BconcoiF-SuperDutyPowetltain/DrivetrsinAug1993

Page 567: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-51 Transrnllelon,Automatic,C6 07-01B-51III I

.,DISASSEMBLYAND ASSEMBLY OF" SUBASSEMBLIES(Continued_

, .,. ,, .

: • ..'_ ' :/'!,_OutputShaft,and, . ,.G0vernor_Assembly,. ............ , .,. . . .......

.... " c

07155-(:

Part PartItem Number Description Item ::Number .. Description

,....1, ..387035-$5 ' ' RetainingRing _ ' ' .:3.:, 7,O,011::'. :CastIron:Governor:SealRing2 '7D011 Teflon GovernorSeal Rings 4_' ',7D220 ,': .,;,;, ,GovernorOil Collector Body

......... ,(Cont_nu.d) 5_' '7060: :"" '. ,' oUtPurSha_t'.6 .7C063 ., ....... ', .GovernorBodyAssembly. . , ,, , - ,. ,,,,

.Disassembly NOT,E:_Make note_oftheposition 0f, thecast iron. ' .governor_.seal,r.ingver,sUs,the two'Teflon_governor ' I " '

...:,1'" _Remove.remove thetheg°vern°rgovernor,body.attaching bolts,and,. -' seal;ring.so_thenew,ring3 will be inst'alled, nthe corr.ect, _[,' i:"

• ' 2. • Remove and discard the retaining ring that location. ' ' ' _ " ' ' ' ': ' _ ' ' " "' '' " : " ' " ' ' " ' r ' k " _d '

secures the governor oil collector body on the 3. Remove the governor seal rings from the, . ' 'output shaft and slide the governor.off the front of governor oi/coltector body.the output shaft. Assembly

1. To assemble, reverse the above procedure.Tighten attaching screws to 11-13 N.m (97-115in-lb).

Reverse Clutch

Refer to the illustra'ti0n_dl!:tl-le"i;e_Vef;se:clutCi_:assemb_ly_::.:; .............. .,for component Iocationand ori_ntatibh:: ......................................' - ....

" 012815-A

1994EconolineI F.150,F-250.F-350/ BroncoIF-SuperDutyPowerlrain/ OrivetrainAug1993

Page 568: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-52 Transmission, Automatic, C6 07-01B-5_

DISASSEMBLY AND ASSEMBLY OF " ',,_SUBASSEMBLIES.(Continued), ' ::::, :,

' p,art _' _" P'_rt " ,; _..Item •'Number Des(:rlptlon _ Item Number Description '

[!:! ' .:" 1 7A089 ! Overrunning Clutch 7 7E085 Reverse Clutch Pressure

Assembly Spring , ._dii_'" 2 78067 Reverse Clutch Hub 8 70403 Reverse Clutch Piston Outer ...," Assembly Seal

d. 3 385044-S Ring (Retains 7B066_in ' 9 70404 Reverse Clutch Piston InnerL 7005) , Seal ....

,_ '4 78066 Reverse Clutch Pressure 10 70 17 t Overrunning Clutch Race ';_,_,:, Plate Inner (Part of 70164) Hub '

. 5 7B442.' Reverse Clutch External 1 I 70406 Reverse Clutch Retainer and

% ",i_"'_ Spline Plate (Steel) Spring Assembly'_" 6 78 t6'4,? Reverse Clutch Internal 12 70402 Reverse Glutch Piston

,, .13 70167. Bolt, OverrUnning Clutch to ".

t,'-.,,, ._ .i(C0ntinued) Case (5 R_q"d) ,

; Dlsassembly'_:i NOTE: Inspect outer and inner overrunningclutch race..1,. Remove {everse ring gear and hub assembly and for scores or damaged surface areas where rollers.. _'. output shaft hub thrust bearing (No. 9) from . contact races. Inspect rollers and springs for"._ reverse clutch hub. excessive wear or damage. Inspect springs and cage.

2_. Remove"i'i°necessary,.overrunning clutch 1. Before assembly of the reverse overrunning-:.. assembly:from reverse clutch hub. clutch assembly into the reverse clutch hub

assembly, note the tabs on one outer edge of theRotate overru_n ng c utch counterclockwise and move reverse overrunning clutch assembly.

• forward and out of reverse clutch hub assembly

' ;: " REVERSE CLUTCH

._.d,. OVERRUNNING ,-_; .,' REVERSE';CL_J-TCH ,, OvERRUtNNhNG HUB ASSEMBLY: CLUTCH HUB ASSEMBLY CLUTCH 78067

ASSEMBLY 78067 7A089 __ ,_

1 _

_'_,,./_;1 _t_ 'j FRONT OF ,', ..

C'UTC. HUB;" . "' DIRECTION OF ' "

•Assembly ":::_ ASSEMBLYNOTE: Check reverse clutch hub thrust surfaces forscores andreverse clutch hub splinesfor wear. D_ZStT-AReplace all worn parts.

:t 1994 Econoline/F. 150; F-250. F.350/BtoncolF.Super Duty Powertrsin / Drivettain Aug 1993z,

Page 569: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-53 Tranlmllelon, Automatic; C6 07-01B-53' II I II I III

" SUBASSEMBLIES (Continued) •

• ::,,"'i:"i :'i: ". li_._2::,,i_!nstallthe reyerse_overrunningclutchassembly,_M" . '2.: .Slide theinner d0wnshift'C0dtrol innerlever 0ut.'"• ,:i,' II' ,j : th'_bughti_e&ont'of the reyerse clutchhub .',, .' . .... from theinsideof the case,.Remove the seal from

,. ",assembly,with overrunningclutch tabs on the . the recess in.the manualdetent lever shaft.front edge, refer to-the illustrationfor component

. :,: ;orientation'and direction of assembly:Seat :,, " ' .._._('%'' - .' .....Overrunn ng clutch(:arefu ly into reverse clutch 1L1_ " _ f-_

hub, and rotate clockwise to seatbearings '• ,,properlyand lock tabs in place.

" ' _r-'_--_'----_"C. _---- -

NOTE CLUTCH• TABS ON ,ASSEMBLY

FRONT 7A089 -_, %

_.. EOGE:'•.."., . ' _,/,.].., .,_ , .CLUTCH'..HUB .: "i';, '..... /7-J. _" "J_ "_ _':_T""_"z--'-'_" "-'_/"-'_' _ X'X..

, _ . ... . . 02330-C

., , :, ' Part ,Di " .... ,• "'": " :.i i_ 7A'1"1'5 ' . '. ' " Inner M_lnual Lever

, OVERRUNNIP,AG _-J Lj// " . .CLUTCH 2 7A39 J, ' .... Outei" Oownshift LeverINSTALLA'rlOt_ " 3 7A256 ' , -', Manual Control Lever

'" IN TO CLU TCI-t. "'HUB 4' '7D'4 1.1 ' ' P.arking_P_awl ActuatingiRod!:_

D12818-A 5 7A26-1" 'Manual'Valve Detent Lever "

Spring6 7D261 Inner Downshift Lever

7 5650 1-$2 Detent Spring Attaching Bolt

Downshift and Manual Linkage 3. Remove the two bolts retaining the park/neutralposition switch (PNP switch)(7A247) and removethe park / neutral position switch.SPECIALSERVICETOOL(S)REQUIRED

4. Remove the nut securing the inner manual lever toDescription ToolNumber the shaft. Remove the inner lever from the shaft.

Impact SlideHammer ,759L-.I00-B, Remove the inner lever and parking pawlPullerAttachment .', .... " , :TSaL-_0t-e :,: .... actuating rod assembly from the case. Slide theShiftLeverSealReplacer.,.',,'_'.-" ,', .TOOL,.7,7288.:.: outer lever and shaft from the case.

Disassembly•1. Remove the nut and Iockwasher that secures the

downshift control,outer leveqtothe transmissionand remove the lever.

Page 570: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B,S4 Transmission,Automatic,C6 07-015-54' IIII I I I II I II '-,

DISASSEMBLYAND ASSEMBLY OF,, . ,_.:.:. '...SUBASSEMBLIES (Continued) . ' .- . .....

• Remove theseal from the case withSlide_":" " ".4.: " Install,park'l'neutralpositioffswitchand ad']Ust" '-_' -".;_" " .::,,ii._'Hammer'.,T'59L-IO0-Band Puller Attachment following procedures underAdjustmentsinthis

....,. T58L-101-E£ section.

i_ 5. Install a new downshiftlever.seal in the recess of ,__A

the outer lever shaft. Slide the downshift lever ";'_".._, .i_: C-8 TRANSMISSION "

•-"_'" _ ' _ " " "PARKANEUTRAL ."'' and shaft into position..._'t' FVREONT-_OF " PosITIONSWITCH 6. Place the outer downshift lever on the shaft and, n,_L:_ 7A247 ,._."T$:

' _ MANUAL • _,,-_--_--'_'_ toSeCure17-21itN.m (12-16ft-lb).witha lockwasher and nut. "13ghtennut -._......': CONTROL / ) / \

i

.','v LEVER , _i" /-. / A / \

7A '_'.

Parking Pawt Linkage _;_:....

Disassembly _.,_,:,_1. Remove thebolts securingthe parking rod guide

: I I I _, ,'/'///'_/'/,,_)'_ \ _\ o'k_j_eJ--J" plate to the case. Remove the parking rod guideplate.

r _. _ _ 2. Remove the parking pawl return spring (7D070).

,:_ \,.________. _ parking pawl (7A441) and parking pawl shaft

__ (7D071) from the case.., 3. Working from the transmissionoil pan mounting;. AOJUSTERTgtP-70010-A surface, drill a 1/8-inch diameter hole through the

RETAINER. (PART OF KIT T91L-1000-Fff:M} 'BOLTS center of the parking plate shaft plug. Puttthe,. O,¢a_-E shaft plug from the case with a wire hook._. ,:. 4. Unhook the end of the parking plate torsion spring

Assembly ;..'" from the parking rod guide plate slot to relieve the ,_i_;1;_- Dip the ne_ seal in transmission fluidMotorcraft tension.

: ' MERCON_=Multi-Purpose Automati__:_: ,:__'"Transmis,sion Fluid XT-2-QOX or -DDX J

(E4AZ-19582-B) or equivalent and install it inthe '_'_'case using shift lever seal replacer TOOL-77288.

• | SHIFT LEVER SEAL

2. ,Slide the outer manual lever and shaft in thetransmission case.

3. -::Simultaneously position the parking pawl 071s7.c:actuating rod into the case and the inner lever on

:-the shaft, making sure the leaf spring roller is_" positioned,in the inner manual lever detent. Install

,!the attaching nut. Tighten the nut to 41-54 N.m .__,,_(30-40 ft-lb).

: 1994 Econoline I F- 150, F. 250, F-350 / Bronco / F-Sup er Duty Power'traln / Drivetrain Aug 1993

Page 571: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-55 Transmission, Automatic; C6 07-01B-55I Ill I

• ,. DISASSEMBLY.AND ASSEMBLY OF:. _

"SUBASSEMBLIES (Continued) ,

...:::;.:___•;.: Intermedlate;,Servo-ApplyLever:._ : ::. ...... .....

Item .. Number .Description Disassembly

, ', 1 -. 7B368 : : ::' Output ShaftrThrustWasher. 1 ,. Working from.the insideof the case, carefully' ,- ,.driveon the:servo apply lever shaft to remove the....:_.'2 ' _7A232 _" ., ,' , Parking PawlActuatingRod ' , ., ntermediate_servolevershaft:retainer (cup p!ug).! .,3 70417 -_.. Parking'Plate TorsionSpring _-The,shaftcanbelwithdrawn from the case by

4 6572 .... Park PlatsShaft Plug, ' hand.I '. 5 70414 Parking Rod Guide Pl'ate

k' .6 .70070 Parking Pawt ReturnSpring , Assemblyr. ;7 70071 Parking Pawl Shaft ' , , 1..,_Hold,theservoapplyJever'in'posltion and install

• ' the.new shaft: , ,_ ., - .... _7.,5..iThreada 114,.20inchorS-32 x,l.,1/4inch.screw, " " ' "_ _" " " .....•. r.. into the,,parkingplateshaft ,Pullthepatking plate _,_, 2'iI ' Usir_gthe'fabricatedt°°lidrive:'theintermediate,. . .......... . ,-servo.levershaft retainer{cup plug)into position '.

,. , , ,,,. ,,_shaft from:thecase.withthe screw. Remove the,_ ,.,in the case:Be sure the intermediate servo lever -,. ,. , _, parking plate-to_sion_spring,and:par,kingrod, ........

• support plate (70414). , shaft retainer (cup plug) is flush with theshoulder" of the counterbore. The intermediate servo levershaft retainer(cuP plug)must be coated with

,Thread!ock.and,Sealer EOAZ-I_19554-AA ,, " ?,!,!(ESE,M4,G204 ,A),o_req6ivalefit.,Uefora• 1;',4,20 X 1_1/4 II'.JCH BOLT

oR,_3; x 1.1/4,NC_-BOLT"_ ., Jn'stallation._ ,, : " ,' ,- " ":, :

• SERvOIAPPLY LEVE[RIP_rAt.l CUP PLUG FI_USH wl _'H

' SHOUL_)ER Ob:.COUNTERSOAE

... _ , ,

I',, IF'+CHOIA I _

I

PARKING PARKING PLATE

TOR ,o.SP.INO '";:,SHAFT 70417 (| _/._2 ll'_CH) " | 2 7m¢_ (,_ IP4CH) Oi A. ORI/i. RO0 ' O | l_qn.I C

7007 1 PARKING'ROD ,

EVER.",.: ::.: "' "PARKING L . : i-_ " , :,ACTUATING ROD .... ; • " '

70411 _ _'_ _''''_''' " " "' : '" : ': '""':" .... " :_":"'"" _':_'

o_ez_.P Output Shaft Hub and Ring Gear

Assembly Disassembly

1. Positionthe parkingplate torsion springand 1 Remove the outputshaft hub retainingring fromparkingrod guide plate inthe case and install the the ringgear (7A 153),parking plate shaft: Place the end of the parking 2. Lift the outputshaft hub (7D 164) from the ringplate torsion spring into the slot of theparking rod ; gear.

guide plate_ ., Assembly2: Installa new parking plate shaft plugto retain the

parking plate shaft. 1. Positionthe outputshaft hubinthe ringgear.

3. Install the parking pawl shaft in the case. Slip theparking PaWI and parking paw1returnspring intoplace onthe parking pawl shaft.

4. Positionthe guide plate on the case, making surethat the parking pawl actuating rod is seated in •. " . , -,the slot of the plate: Secure the plate with twobolts end Iockwashers. Tighten bolts to 17-21

'- N.m ( 12-16 ft-lb).

Page 572: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-56, Transmls$1on,Automatic,C6 07-01B-56II I

DISASSEMBLY,ANDASSEMBLY OF .... ";,,_,,!-SUBASSEMBLIES(Continued)., - '_ '

I •.. .( .

,_t..,._",--2,: Securetheoutput shaf,t,hub,withthe retaining ....:' 2. Mountlorq_econverteronthefront0ilpurfip " :_"_;:"_. if_i ,I : _. ring.Make certain that the snap ringis fully support andgear with the splinesonthe one-way ""

;,,, t ,,! engaged with the groove, clutch race engaging the matingsplinesof the

I front oil pumpsupport. The torque converter hub ,_will then engage the front pump drive gear• _-_

' I • • GEAR RETAINING "_;'

"_. | _. • 7A153 !' ' _ RING 3. Hold the front oil pump support stationary and try

L to rotate the torque converter counterclockwise.

The torque converter should rotate freely without ,_any signs of interference or scraping withinthetorque converter assembly.

., _ 4• If there is an indication of scraping, the trailingedges of the front pump supp0_Lbladesmay be,

ii!!""_ i interfering with the leading ed,_:s of theimpeller

_;:,,_,, _ _ _ . . - blades. In such cases, replace_ihe'torque •:_' • _ converter. _'.

: ;', t ,_:_',,. TORQUECONVERTER

Torque Converter Checks

One-Way Clutch Check +;

SPECIALSERVICETOOL(S)REQUIRED

Description • To_olNumber._Convortor Clutch Torquing Tool T76L.7902-C

Converter Clutch Holding Tool T77L-7902-R

1. Insert the Converter ClutchHolding Tool FRO_TPUMP I'_T77L-7902-R inone of the grooves in the stator SUPPORT :_'..... .thrust washer.

2. Insert the Converter Clutch Torquing Tool . ,_,,.. o_zl.eT77L-7902-C in the torque converter pump drivehub so as to engage the one-way clutch. ,,Stator to Turbine Interference.Check ,.

3. : Attach a torque wrench to the converter clutch _+.!_+1.+Position the torque converter on the bench front :.- +_:-, "torquing tool. With the onmway clutch holding tool :"::, side down.'

,'i held stationary, turn the torque wrenchcounterclockwise. The one-way clutch should 2. Install a front pump support to engage the mating

.,'i.' Iockup and hold a 14 N.m ( 10ft-lb) force. The splines of the front pump support, and pump drive _+one-way clutch should rotate freely in a clockwise gear lugs. .._._,,_,:direction. Try the one-way clutch for lockup and 3. Install the input shaft, engaging the splines with :_hold in at least five different locations around the the turbine hub.

torque converter. 4. Hold the front oil pump support stationary and4. If the one-way clutch fails to lock up and hold at attempt to rotate the turbine with the input shaft.

14 N.m (10 ft-lb) torque, replace the torque The turbine should rotate freely in both directionsconverter, without any signs of interference or scraping

Stat0r, to Impeller Interference Check noise.

1.' Positionthe front oil pump support and gear on abench with the spline end of the support shaft .pointing up.

_i

Page 573: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-57 Transmission, Automatic, C6 , 07-01B-57 :....r"DISASSEMBLY AND ASSEMBLY OF.,..... LSUR.ASSFMREIFR..I_onfinuerI_ r

• L

" ")_._,'--..._:'.washer"maybe'worn.allo_ving the'frontoil pump;".-":, _'"" '" '..... '' ' " = TORQUE CONVERTER ' '

..... :: support to hit the turbine. Insuchcases. the ' , II ' ' .. _.ENDPLAY• " torque converter,must be replaced. " 1 I .CHECKINGTOOL

II ' TSOL-7902.A' .... q ' " " _' I I INSTALLED INTO TORQUE• Checkthe conyerter c_ankshaft pilot for nicks • _ ii , CONVERTER-7902

'. or damaged surfaces that could cause ,• ,, ,interference.when installing the torque THREADED'.._'--------_-J " [-- /

converter into the crankshaft. Check the,,,,.:,", tocque;converter.front.pump drive hub for nicks

, , , ......:or;snarp, edges,that would damagethe.front oil. pump seal.

INPUT SHAFT7017

SUPPORTSHAFT " O12¢J32"A

.2. ': Expand the sleeve.in,the,turbine spline by. , " tighteningthe threaded nner post, untilthe tool is

, securelylocked into thespline.

, ,: 3.," "At.tacha Dial Indicator with Bra_:ketry..'TOOL'4201-C,t0'the_t0o _Post on the :dial .

,. , ,, -,_ ,:indicator:buttomo0,the;torque converter, pump' • •• _',;driv,e;hub:';andsetl,the,_dialfface:a'td(ze'ro)."',_ ,'/.,,i "i

DIAL INDICATORWITH BRACKETRY END PLAY

TOOL-420 t-C TOOL

/ _. TSOL.7902.A

TORQUECONVERTER

7902D4822.B

TORQUE

Torque Converter End Play Check CONVERTER

SPECIAL S E RVICETOOt_(S)_REQUiRE D:'_.. : .....

Description Tool Number

Torque Converter End Play Checking " T80L-7902-A :"

Tool , . ., . . : ',

Dial Indicator with Bracketrv TOOL-4201 -C

1. Insert Torque Converter End Play Checking ToolT80L-7902-A intothe torque converter pumpdrive hub until it bottoms. " , •,

DS723-B

1994 Econoline I F. 150, F-250. F-350 / Bronco / F-Super Duty Powertrain / Drivetrain Aug 1993

Page 574: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-58 Transmission, Automatic, C6 07-01B-58

DISASSEMBLY AND ASSEMBLY OF

•,".SUBASSEMBLIES•(Contlnued) :'i' _.,_.

t

_ 4:, Liltthe tool upward.as•far asit,will,go and note,. , ........ :, , ' ,... ).':' i: • ;theindicator.reading:,The, indicator,readingis the:.,.:_ .- ourpu,r,'sHAFr. • , ' " ' , :.._ _,

_-,,, total end_playwhich the turbine and front oil pump THRUStWASHER '",_.,;. :"' support,_hare. Replace the torque converter unit 78368

'! if the totgi end play exceeds the limits. End play _,

'i,i" inSpeclflc'atl°nSthissection.'_ . are listed under specifications , ,. ::..._-_'__,: 5. Loosen the threaded inner post tOfree tl_etool.

,,,, _:_:". and theni"remove the tool.from the torque output SHAFT .PARKINGGEAR i'" :" _._._!

':!):• converter. 7A233 _ :' ASSEMBLY

% ;_',

'__i'ransmission, ;"

/" ' .SPECIAL SERVICE TOOLIS) REQUIRED

o..o.,o,,ooi 1I'-';(]ialIndicator _,v_i_hBracketry TOOLo420 I.C

4, Place th_:itransmission case in a holding fixture, ourour2. Tap the r_verse clutch piston into place in the SHAFt',, case with'a clean rubber hammer. 70a0

'3'. Install the reverse clutch piston spring retainer:'_ assembly in the clutch piston. O12819-A

,.4". Hold the_one-wayclutch race (70 17 1) in position 7. Position the collector and tubes in place on the :. '_.,.,_q-: and install the attaching bolts. Tighten bolts to rear of the case• Install the attaching bolts and::, 25-33 N:_ (18-25 ft-lb) .... • tighten to 16-22 N.m ( 12-16 ft-lb).

r51" Position the transmission case with the front end 8. Install the output shaft and governor as anfacing downward, assembly. : .-_:_._;

6. Position the output shaft rear thrust washer (10) 9. Place a new gasket on the rear of the ''_' __:"and the output shaft parking gear on the case. Do transmission case. Position the extension housingnot re-stake the thrust washer, on the case and install the attaching bolts.

............................ ' "13ghtenthe attaching bolts to 34:47 N'm(25:35 - -ft-lb).

10. Coat new gasket with petroleum jelly and positionon the servo cover.

11. Position the servo spring on the_pistohrod.

12. Insert the servo piston rod in_thgcase. Install the•. servo cover with the attaching,.'ib_blts,making sure-

that the identification tag is in place. Tighten the..... attachingboltsto 19-27N.m(:14-20ft-lb)..,

_' t_NOTE: Do not rotate hubduring assemblyover inner - , "-,;,.

;,;race.,; ' 13. Alignthereverseclutchhubandoverrunning :/. clutch with the inner race at the rear of the case. :"

_ Install hub,assembly while applying pressure to '.-_seat it on the inner race. ,',-;'_

' _" 1994 Eco_oline I F-;50. F-250, F-350,' Bronco / F-Super O_t,/Po_ertr a_n/ Ofi_etrain Aug 1993

Page 575: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-59 Transrnlselon, Automatic, C6 07-018-59• Ill I I ;

. ;,'ASSEMBLY.(Continued) " • '

...." ': .::NOTEi.The numbei of-steel.and frictionreverse clutch :.: 22. tnstall,forwardClutchhubneedlebear!ng ":.'.:..', " ,lates,for the reverse-c utch (7B 164) assembly,w ,_J.." • .;-:assembly-on.the:forwardplanet carrier ht_b. ....."

• ; .varydepending onengine application.. 23,. Idstall f0rwa_'dp!anetcarde_..assembly into the14.:" Install the reverse clutch plates,,starting with the , forward ring gear assembly.

. .-rear'clutch pressure Spring(7E085) next to the 247 Install npqt:shell and,sungear assembly, aligning.... i.,,i .,-clutch-piston' and following with steeLand friction': ': , ,. thesun gear Splines,witt_pinion,gears'inside the

:,: ::.,: plates alternately. Retain them with petroleum " ' . planet,.assemblytand the, tabs.on the input shell.'.i i " ' """jelly" If new:reverse clutch composition plates are : '",with.the:ears on the,inter_mediatebrake drum.,; .:,:;'..ibeing_used;_,soak.themin,cleantransmission'oil',; . :.... ' " ' '

. . ' .... - Motorcraft MERCON _Multi-Purpose Automatic .... : • ' ' .:. ........ " ,, , " :,,Transmission'FIL_idXT-2-QDX or,DDX ......... , .... :, .. , ou'rPur

,.. : (E4AZ-,19582-B) or equivalent for fifteen minutes, : :-.,,_;ERMEO.A_:E' SHAFT• . • 8_AKE' ORUM ; "

: ,.._:T._,.beforeinstallatied.,Install theclutch pressure . ' , . , ' 7o0_ .,: C_". ' _ .... ..... .7_6o

:.... ,',.plate.and,the:retaining',ring,,_'Test'theoperation/0f ,:_"_, , . ",., •..i',....... the,reverseclutch_by'applyir_g_air pressure:at the'"-_! • ,

,, :.15. Install.output Shafi ring'gear and hub assembly.

._ Install output shaft retaining ring (377155-$5) in '_ __

,the.groove on the output shaft. '

REVERSE

" , .70_6,t.: ',, "' _ . "/',,, :..... ,...... "

_/ ' .... o6475.B

• ,, . . 25., Install this forward geartrain assembly (from the "input shell to the intermediate brake drum) as an ._....... a-ssernbly into thetransmissi0n.- "26. Insert the intermediate band into the case around

the intermediate brake drum. Install the bandstruts and tighten the band adjusting screw

OUTPUT/ sufficiently to retain the intermediate band.SHAFT"

SNAPRING 7060 RETAINER 27. Place a selective thickness bronze thrust washerPLIERS , , RING

• . ' ' ".... -::'- .....07'1s_-C' ": (No. 1)on the rear shoulder of the front pump

16. Install front a_J r:ea'(reve_e!l_iao;et!c:arfi_ti'thri_Si::'!!":!i • supportandretain it with petroleum jelly. If thewashers (No.;::7_aridNd:"8)dnthe i'e=verse'plahet.' '- .... end play was not within specification whenchecked prior to disassembly, replace the thrustcarrier assembly; use petroleum jelly to hold inplace during installation. Install reverse planet washer with one of proper thickness• Refer tospecifications at the end of this section for

,.. carrier'assembly into output shaft ring gear selective thrust washer thicknesses. 'assembly and instalYretaining ring (377155-S) tohold in place. • Using two 5/16-inch bolts three inches long,

:17_. Install the intermediate brake drum thrust washer : make two alignmentstuds. Cut the heads from,:.... (No.,2) on,the intermediatebrake drumhub:.,., ,. the bolts and grind a taper onthe cut end._ • ,-

. Temporarily install the two studs opposite each:18'. Insert tile forward clutch assembly into the .',' " ' ' other in the mounting holes of the case. Slide a

intermediate brake drum (direct clutch new oil pump gasket (7A.136) onto the studs.assembly). Position front pump support and gear, on case.

19. [nstalt the forward clutch hub thrust washer (No. being careful not to damage the front oil pump4) onto the forward ring gear hub assembly, seal on the outside diameter of the pump

20. Install the forward ring gear hub assembly into the housing. Remove the aligning studs.forward clutch.aligning the internal splines of the • Install six of the seven mounting bolts and . •forward clutch friction plates to the splines on the tighten to 22-40 N.m (16-30 ft-lb). ' .• '

-- ring gear.

21. Install the forward planet carrier thrust washer(No. 5) on to the forward planet assembly.

1994Econoline7 F;-t 50.F;250:F;3507 ero_5n_/F;-S u_O uTyp_in-A_ 19g 3

Page 576: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-60 Transmission, Automatic, C6 07-01B.60. ,11 . I "_" I

ASSEMBLY;(Contlnued) . ........

' .28..-Adjust the intermediatebandas detailed.under. - 33, Install the torque converter assembly: ": ..... ,' .: :..: ._._....:" ,Adjustme0ts and install the input shaft with the ." 34'_.Install the ir'ansmission inthe vehicle as detailed

,_; ' long splin_dend inserted into the forward clutch in this section.cylinder a'ssembly.

29. Install Didllndicator with Bracketry TOOL-4201-C , - !J;_',' at the se_.enth front pump mounting bolt and INSTALLATION _/

,.check the,transmission,end play as in Steps 4 5 -"and 6 of Disassembly. (See Specifii:ations at theend of thiS,section.) Remove the tool. Transmission, F- 150-250-350, 4x2 and 4x4 i;. . 4_,

• nstall.i'he seventh front pump mounting bolt 1. 13ghtenthe converter drain plug to 11-37 N.m ....... '_,__:._ and tig_.!en to 22-40 N.m (16-30 ft-lb). (8-27 ft-lb).

, "_ ._'_ 2. Position the torque converter on.the transmission '. ,:.'_,':'_ making sure the converter drive,Jets are fully . •

;_ ,_ _ engaged in the pump gear. _:,:.

_'._ "_ --,., _ 3. With the torque converterp?ope[.ly installed,"

_.; place the transmission on thejack. Secure thetransmission to the jack with the.chain.

4. Rotate the torque converter untilthe studs and;. drain plug are in alignment with their holes in the

flywheel.

_,J_ CAUTION: The torque converter must restsquarely against the flywheel. This Indicates thatthe converter pilot is not binding In the enginecrankshaft (6303). Do not allow converter driveflats to disengage from pump gear.

5. Move the torqueconverter and transmission_Ro,_Jro,L forward into position, usingcare not to damagePuMP ASSE_lSLY

7At0:] the flywheel and the converter pilot.6. Install and tighten the transmission-to-engine

attaching bolts to 55-67 N.m (40-50 ft-lb) ongasoline engines and 68-88 N.m (50-65 ft-lb) ondiesel engines.

7. Remove the transmission jack safety chain fromaround the transmission.

81' Position the No. 2 Cr0ssmember to the frame side - " -rails. Install and tighten the attachingbolts to ,58-77 N.m (43-57 Ft-Lb).

9. Install transfer case on F-Series 4x4 and Bronco.Refer to Sections 07-07A and07;_-O7B.

10. Position the rear engine support-and _earenginesupport insulator assembly above thecrossmember. Install the rear enginesupport and

o647z.s insulator assembly-to-extension housingmounting.. bolts and tighten the boltsto specifications as.. ;-: ,

30. Position the main control valve body to the case listed'at the end of thissection..making sure that the gear selector valve rod 11. Lower the transmission and remove the jack.

. assembly and downshift detent inner lever._assembly are engaged. Install and tighten the 12. Secure the rear engine support andinsulator

attaching bolts to 11-14 N.m (95-125 in-lb), assembly to the crossmember with the attachingbolts and tighten them to specifications as listed

NOTE: Do not grind or sand surfaces. Use a gasket at the end of this section.scraper or wire bruch to clean old gasket materialfrom transmission oil pan and transmission gasket CAUTION: Make sure the vacuum line Is not

pinched or damaged during transmissionsurfaces, installation.31. .Clean the transmissionoil pan and oilpan to case

gasket surfaces thoroughly. 13. Connect the vacuumlinehoseto the throttle valvecontrol diaphragm assemblymakingsure that the

32..Using a new oil pan to case gasket, install steel vacuum line is in the vacuumretainers. :_... • attaching bolts,.securing the transmission_oil.pan

:to the transmission case. "13ghtenthe attaching 14. Connect the oil cooler tubes to the transmission. "_bolts to 11-16 N.m (8-12 ft-lb).

•' :,'.• 1994EconolineI F.150.F-250.F.350/Stonco/F.SuperDutyPower_rainIDrivetrainAug1993

Page 577: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-61 Transmlnlon, Automatic, C6 07-01B-6 iml I III

," :INSTALLATION (Continued)

_-._,:.,"i";._::-. •_i,15.",_.,_:)nnect;tbe:downshiff control,oiiter lever, and_-_', , 21 _-Eill_i}hetrangmissio_fi;tothe'prO_f le_l with,the', =' ."' .....cable controls to their respective levers on the ' . specified oil.

,, transmission. Refer toSection 07-05. _.22:1,Adjust:theshift.linkageas reclui_ed.Refer to

6. Secure the starter,'motorin place with the, ...... % .... .,'SeCtionO7-O5:Connectparklneutral position':i ,_:_attaching bolts:Connectthe battery tostarter s ' ,: . switch'elecfi'iCal:conne_,tor. . , , "

_, • relay cable to the t.erminal on the startermotor., i 23.;.Rem0vesafetY,,stands,_and Iowet'.vehicle. ....'

. : ,17._' Installa new.O-ring on the, lower endof the ,, '. 'NOTE i.Whenthe.battery.hasbeendisconnected and ,, :,, , '! : ::_--,:,transmissio_,lube;oilinletshorttube'andinsert the :. recohnected..some'abno_aldrivesymptoms may,

" ,! lube oil inlet,short tube inthe•case: .... . " ' '_ ;'_ , ::occur,while,thepowert_'a nControl•module, ., . ' , -i. -18._,Secure)the converter-to-flywheel attaching•nuts.,, _(PCM)(12A650)!.relearns:itsadaptive_strategy. The

• .. , , andtighten them to 28-45 N.m (20_34 ff-lb). ..... , :_vehicle_may,need:to:be;driven,10miles0rmore to

', ', ._,19.";Install,the:transmissiOn_hOusing,,dove_.a_rd_S_ecdre_!.'_;:_relearn:the_st_ategy_ ,,' " ,. '_ :::;:_ _:,. :.:,it,with:theattachingbolts. . . , ; : . .. i.. ,24: ,:condect the battery ground cable..-20.":Connect thedrivgshaft!'i;:_:_":!:"! ::_'' i " :,_: ' "..... " '

Page 578: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

I

07-01B-62 • ; .. Transmission, AutomatiC, C6 " •...... 07-01B-62I III _

{Contlnuedl . ' " / " ' ;" '_NSTA_LAT_ONi

.,;Cro|sm.emberdnstallatlon;F-250*3504X2'and 4x4,. '.... ' _-' ' ' " ' ,_ '.. I,

_. _!_ _J - •

V!

/

;: INSULATOR INSTALLATION .... ;

. i

FOLLOW HOLE PATTERN A

, . FOR C-41 TRANSMIS,_ON

• VIEW Y TYPtC, AL INSTALLATION VIEW Z

D7421-E

I

Page 579: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B-63 Tranlrnlaalon, AutornaUc, C6 07-01B-63II '"

' 'INSTALLATION :(Continued)

i

.... ' :Part- Part ,,."' " ' liem. - Number Description Item _ 'Number, ,_ De,.scrlptlon

""" 1 7R314 Rear Engine Support 6 : 6"0091 -,. Rear Engine Support• Bracket,(RH) Insulator

2, 5060 " Crossmember ' . 7 , -388824 '",:, .. ,B01t 81-i08N.m

• 3 7F468 , • • Rear Engine Support (60-80Ft-Lb)Bracket(LH) 8., 4A263 ./ • Rear Axle Dr_ve Line

.'4 802114 ., _ ,Bolt', . . ,..: :.... ,Vibration'Damper" "" " ' ' ; 5-., 800937 • "' Nul,58-77 N.m (43:57Ft;Lb) 9 .t',16211,,9:45 ' '• ,Nut and, Washer Assembly

._,... " ' : _,L • .,. , ._,. :_:!.._7-7_103N.m:_(57-75 FI.Lb) '• '(Continued) , ' ....... "" ' ....

., ,. ,, ,. ...... ,

':,'iTransrnission. E-150,!250-350, ,. ' -, ,, 12; Connect the transmission.shift cable to the,

,o 1.. Tighten the converter drainplug to 11-37 N.m ' transmission control levers.(8-27ft-lb). • Whenmakingtransmissioncontrol

2. Position the torque converter on the transmission _,attachments, new,retaining ring.and grommet,:,.: ..... 1,,freaking sure,the conver,ter,drive flats are fully , r J _ ::!_should'!always:be_used_(see'Removaland; ..... , ;-engaged in thepump gear. ,, :/,,.:_ln:stallati0nin_SeCtibn,OY,_O5):.Noteprecautions

3:: _,.Withthe torque converter pr,operly installed." -,: -.,,,,_necessar:y_toprevent:grommet damage..":_ place'the transmission on.the jack..Secu_'e the . , ,-!i_edor, m,alinkage_adiustment as outlined in::section:07_05. ' ', '..transmission,tothejack with the-safety:chain. , , ' :

"- 13 _lnstali the_.tr.ansmission,housing cover_and tighten. . :_4.- : _Rotateithe,torque'converter:until'the studs'and . _..,,:the attaching bolts;lO :l',7-2.1'lN.m'(12-16 ft-lb) for

, : :_dr.ain:plugare'in alignment-with their holes in the , , :,-all:e:xcept-7.:51_,_engiqe:application:,Tightento 4;7" flywheel. .: _.N.m,(35,54,in:lb),,fo_:7.:5Lengneapplications"

: ,, NOTE:-The torque,.conve_ter mus't_restsquarely. :,,.,.i,,,: .....,,14 ,.,-Position,the,,starter_!motor nto:thec6nvef, te_'- .. ' "flywheel..This_,indicates,that the'converter ' . _ ,housing:andiinsta,ll._the,_att_chi,ngbolts:,Tight,eh:th,e;,:,

' :, -pilot is not binding.in:the:enginecra:nkshaft. Do not bolts to 54-68 N:m (40-50 ft-lb) on gasolineallow converter, drive flats to disengage from pump.., engines and68-88 N.m (50-65 ft-lb) on diesel 'gear. engines. Install the battery to starter relay cable.5. Mo_,ethe torque converter and transmission 15. Install the driveshaft.

forward into position, using care not to damagethe flywheel and the converter pilot. 16. Remove safety stands and lower vehicle. •

6. Install the converter housing-to,engine attaching 17. On V-8 engines, install the engine air cleaner hotbolts. Tighten the bolts to 55-67 N.m (40-50 ft-lb) air tube. Install the bolt that retains the oil filleron gasoline engines and 67-87 N,m (50-65 ft-lb) tube to the cylinder block (6010).on diesel engines. Install the "' 18. Connect the park / neutral position switchconverter-to-flywheel attaching nuts_ghted_tl_e:i:,,_,,: ' electrical connector.nuts to 28-40 N.m'(20_30 ft-lb)_/'_:,_t:-'::.:-_:::_"_':_' ._ :....

19. Fill the transmission to the proper level with the7. Install the crossmember:lnsta ,the,rea_"engne! __", specified oil.

support and rear engine support insulatorassembly-to-crossmember attaching bolts and 20. Raise the vehicle and check for !ransmission oil

• , .nuts.Tighten the bolts to specifications as listed leakage. Make sure the transmission oil pan is' at the end of th s section, securely attached. Lower the vehicle and adjust

' the downshift and manual linkage. Refer to8. Remove the safety chain and remove the jack Section 07-05.

fromunder the vehicle. Remove the enginesupport bar. NOTE: When the battery has been disconnected and

, .:,, reconnected, some abnormaldrive symptoms may '_ ' 91 _Install a new O-ring:on the lower end of.the :-' occur while the powertrain,control module.relearns its

•_' :.' - : transmission oil fille'r_tube_,ndinsert the oilfiller • adaptive strategy. The vehicle may need to be driventube and oil level indicator in the case. 10 miles or more to relearn the strategy.

.- :10. ' Connect the vacuum.line hose to thethrottle valve •. ....21. Connect the batteryground cable.control diaphragm making sure the steel vacuumline is secured in the vacuum diaphragm clip tube 22. Install the engine compartment cover.retainer.

11. Connect the oil cooler tubes to the transmission.,

-" .t 99:4 Econoline-/F-t 50:F;250.F;3507 B_F:Super Duty Powertr=in / Orivetr,=,inAug 1993 ..

Page 580: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B-64 Tranemlss!on, Automatic, c6 _ 07-01 B-64

INSTALLATION (Continued) , :+

, ,,Crossmember.lnstallstlon;E-1:50;250-350 "" , • +? ; - )i• ,.. + ...

VltW V

; " ' RE TAI_I(R

6C_JI'i COt:ORCODe t UOLTa+,,ow,+,s..,e_ '_

, ,++++•.. :+ ,. ISG 70 I:T LB) '

/O_X

_'|r" t SLOT USE SHORT SLOTS

+++ ,++-+++' ....MOUNT WITH C6 AUTOMATIC TRANSMI_*_,ION IEW ._._+..++

+++ .... + """'+++ ."_ '++' " ('110_' Mk.MH+ H + ' •'+++'_"[$

" _i l ,+ V,EW Z .e,,,2S +_; . ++' . .

MOUNTC _,AS.SlS Cm

i NuT ANO W a+S,I_R

F AO_ t; 4,35n

;. _C/M I$¢= 1¢_Fp LPI+

_ "+ : O4 7:30.2A ''+,+' +- _+ ! ,3;_+ ++ -_ +',+,(_,S,,+ +., :

•? CLEANING AND INSPECTION .... !;+'+

Transmission The compositionclutchplates,bandand__J+tjs_lmpgrtant to completely_clean al! synthetic seals should not be cleaned ins vapor ,;+'i

transmlsslo n components, Including torque degre-aser or Witli any type of detergent solLJti0n,i .... +__\:converter, transmission oll cooler, otl cooler To clean these parts, wipe them off with a +++ /tubes, main control valve body, governor, all lint-free cloth. New clutch plates or bands shouldclutches, and all check balls after any be soaked in transmission oil specified for thattransmission servicing that generates transmission type for fifteen min_es beforecontamination. These contaminants are a major being assembled. •cause for recurring transmission troubles and " _;_+

,must be removed from the system before the +_++_+• transmission is put back into service. The + +

cleanlng of debris from the forward clutch piston ++TransmissionCase+ +?._ • . . . . ?

t and forward clutch piston check balls are often '_-_+t.Inspect thetransmissioncase for cracks and '_+' +' ",• omitted. This omission can lead to a repeat " ' •strippedthreads.•Inspectthe gasket surfaces '.

eer:vicing of the transmission, and matingsurfaces for burrs. Check the vent for+ "+-:Dur!ng overhaul, inspect all hardware for evidence of obstructions, and check all oil passages for -'.+ov.e_rheating.Any overheating will be indicated by heat obstructions and leakage. ., •:..._stained blue Surfaces. Replace any parts that show 2. Inspect the case bushing for scores. Check all _evidence of overheating, parking linkageparts for wear or damage.

Clean the parts with suitable solvent and use _ If a transmission case thread isdamaged, service _moisture-free air to dry off all the parts and clean out :" kits may be purchased locally. To repair a +!-!oil .passages. damaged thread, the following procedures should

i!_ be carefully followed.

+_• 3. Drill out the damaged threads using the same.... : . drill size as the thread outside diameter. For "+

, example, use a 5/16-inch drill for a 5/16-18 ....._ thread.

,.r¢

:_:_ 1994 Econoline/F. 150. F-250, F.350/Btonco/F.Super Duty Powertrain I Drivettain Aug 1993

Page 581: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

0__7-01B-65 Transmission, Automat Ic, C6 07-01B-6,';

•'•CLEANING AND INSPECTION (Continued).... ,

: .i. IY4. .i,:Select the;proper sl_cial tapand.tap the.drilled' ..,. • 2.. _lnspect'all valveand.plug bores'foi'Lscores' Check,i '" " : r'h01elThe tap is marked.for the,size of the thread _ ",all oil passages for obstructions. Inspect the

....: _.being repaired., Thus. the special tap marked • _ •', checkvalve for, freemovement., Inspect all mating' 5/16- 18 will not cut the same thread as a , surfaces for burrs 0r;distortion Inspect all plugs

,, ,, ..standard.5./, 16-,18:taP..The tap cuts a'thread, _ ':., . .. ;and,valves,for.burrs 'or.scores. Use Crocus cloth.. , .,_.,,, large enough tOac'c0mmodate the,insert; and - ' ' _to,polishvalves_andplugs._Avod rounding the,

:" ". '-after,-theinsert isinstalled.,the original thread size . .... - sharp:edges of_thevalves andplugs'with the :.... (5/:16-,18), is restored: " ' cloth_.... _ : " :r"...... R ' " "

•.-::, ,,...... i5: ;..Selectthe pr,0per coil.inserting.tool..These iools, : i,. 3..;",_lnspect.all,spri0gs fordistortion',Checkall valve_s -"..... ,',: ,,,:.", ,-.;are_marked, withthethread_sizebeingrepaired - ,,, -, "-andp!ugs for,:freemovement n,the r respective

...... ;,,,_:,_,Place the:insert on,the tool and adjust,the sleeve:'. ,... :, ,.:bores.,:,Valvesandplugs,_when;dcy., must fall from:_... _,,•to.thelength of,the insert,be ng used_Press,the. - .. ,,..their.:ownweight_n the r r.espectivebores.i ,'.,.. ihset:t a'gainst the face of.the,tapped, hole .,.'rurln. • " • "__,'_:.'.i_the'tool clockw ,se,andwind,the,:inselr.tir_to,'the:;,,;_i,_: ,,i ;_ 4. _,,Inspect:,theseparator,:plate_screen for '' _ . ' .obstructions•-.The screen must be clean and free

•. ':.,: ,._ ,,", ,hole untilthe-insert is;;;l!/,2turn;below, the face! . ..... :. of foreign material. If,contaminated, remove it.:6.--_ Working through_the,,insert; be_ndtheinsert•tang ..... , from valve body separating plate, clean in a

• .:straightup and down untilit breaks off at the suitable solvent; and thoroughly blow clean withnotch, compressed'air.

... , ,. °:7:,_,_.,,,.mproper y,installed,inserts canbe removed with-... .-,5,_. _Roll:the!manualSh ft:va ve onlaflat surface to,, . _' _,, .":_.,,_theextractor.tool.. Place.the,extractortool in the.. ' ..._.check'for bent,conditi0n.

•"_;insert with the blade resting,against the'top co I",",-!1./.4;to 1:/.2_turnawayJrom the end:of the:coill ..............

• . !_ _,Tap the,too sharply with a hammer:Until the blade -:-.... ,. cuts,into the insert.Exert downward pressure on Clutches "

,, _:.theloo/andturncountercockwseunt the insert ..is,removed. Forward Clutch

,_ • . 1., 'Inspect the fr,ont'clutch cylinder thrust surfaces.-ik._....... -.,- ._, ,.;..clutch:piston:,bo_e:andclutch plate,:serratiOns, for,,

-_ scoresor burrs_Minor scores,,or burrs_maybe ",:,,.,:.......... :'.Extension Housing . • ' ' i ......... . ', removed:with cibcus_cloth, ' Replace the"forvvard '_

.1_.; Inspect the extension housing for cracks. Inspect', clutch cylinder if it is badly scored or damaged•• the extension housing gasket surface.for burrs or.' 2. Check the oil passage in the f0rward clutch

warpage, cylinder for obstructions• Clean out all fluid

2. Inspect the extension housing bushing for scores passages. Inspect the clutch piston for scoresor wear: Replace it required, and replace it necessary. Inspect the clutch

piston check ball for freedom of movement and '31 Inspect the output shaft and extension housing proper seating

seal for hardness, cracks, or wear. If the output 3. Check the disc clutch release spring for distortionshaft and extension housing seal shows wear orand cracks. Replace the spring if distorted ordeterioration, replace the output shaft and, _. ,

extension housing seal. ' " ' " " " _ cracked..

4. Inspect the seal',counterbore;andrernove, a _burrs_:_ : 4. Inspect the composition clutchplates, steeland scores with crocus'cloth: ..... clutch plates and clutch pressure plate for worn

or scored bearing surfaces. Replace all parts that, aredeeplyscored•

" '_ _ 5. Check the front clutch cylinder thrust surfaces for.,, Main Control Valve Body scores and the clutch cylinder splineS for wear.

.11 • Clean all parts thoroughly in clean solvent, and 6. Check the splines on the stator support for wear.' blow drywith moisture-free compressed air: If ' " ' Inspect the bushing in the stator support for.

...... :,. _- the main,control valve,body, screen gasket is_..... _. _ Scores..Check the input shaft for damagedor.wor.nsplines. Replace inputshaft if.the,splines_ ..:.,; ..... ", '.'. .: removed; the gasket,.should not be.cleaned:: . ....

in a degreas'er, solvent or any type of are excessively worn.•detergent solution. To clean the gasket, wipe Direct Clutch

. it off with a.lint-freecloth,lf gasket shows_ 1.. Inspect the direct clutchdrum band surface, thewear or deterioration, it should.bereplaced.. bushing, and thrust surfaces for scores. Minor

scores may be removed with crocus cloth. Badlyscored parts must be replaced.

2. Inspect the clutch piston bore and the pistoninner.....and outer bearing surfaces for scores. Check theair bleed ball valve inthe clutch piston for freemovement. Check the orifice to make sure it isnotplugged.

__ " 1994 EconolinelF-150 F.250 F.350/BrOnCo,F. r " • "

Page 582: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-66 Transmlsllon, Automatic, C6 ; 07-01B-66

,CLEANING, AND'INSPECTION (Continued) _ :_

:3:_ Checklhe oiLpassages for obstructions.,Alloil,_ Planet Assembly.and-Cent_er Support _-'_";- '. : _", :.:• ':_,"passage_must, be clean and free of obstructions._ Individualparts of the planet carriers are not

4_ Inspect thbclutch plates for wear, scoringand fit serviceable.

',. on the rear clutch hub serrations. Replace all 1. Check the pins and shafts in the planet i_:_".._",plates that are badly scored, worn or do not fit assemblies for loose fit and/or complete

.. freely inthe rear clutch hub serrations, disengagement. Use a new planetassemblyif5 I. Inspect the clutch'pressure plate for sc'oreson either conditionexists. Before installinga planet

'. the clutch, plate bearing surface. Check the clutch assembly, the shaft retaining pinsshould be . _ :_:_

.:__ release spring(s) for distortion, checked for adequate staking. If necessary, -.,_:, 6: The clutch piston has a check ball similar to that restake the pins before installation. When

",' shown. Inspect the check ball for freedom of restaking, the retaining pins must not be drivenS•,. movement.and proper seating, into the carrier any further than 1.01ram (0.040-• inch) below the surface of the carrier."

•; 2. Inspect thepinion gears-for damaged or 'CLUTCH excessively worn teeth. _:..

';._,_: 3. Check for free rotation of the p'i/_;6ngears.

':_ P,sro,'_."!:_ SEA Staler Support

.... 1. Inspect the stator support splines for burrs'and ""• _ wear.

2. Check the oil ring grooves inthe stator support• J BALL for nicks, burrs or damaged edges.

3. Check the front and rear bushings of the stator.- support for wear or scoring. Ifworn. the forward

CLUTCH " clutch will wear into or score the staler support,. P_sroN and damage the Teflon _seal rings• Replace

• ._ stator support assembly if worn.

Intermediate Band Serve '

1. -Inspect the intermediate band serve bore for .... _......... _-,-cracks and the intermediate band serve piston for, "

_ damage,andtheintermediatebandservepiston " "bore and the intermediate band serve piston stemfor scores. Check oil passages.for obstructions.-0Z_145.1C _Replace damaged seals. _- " ;

2. Check the serve spring and sei','_/Oba'hd strut(s) 'for distortion.

:.. 3. Inspect the cover seal andgasket cover sealing

Governor :_... surface for damage. " i,'"- " '1._i.'Inspect the governor valves and bores for scores. . :_: Minor scores may be removed from the valves '

:'? w_thcrocus cloth• Replace the governor =fthe Oil Pump!_; bores are scored or if the valves are scored•i_:_.•beyond the point of being able to be cleaned. 1. Inspect the mating surfaces of the pump body and !-_

2.:. _ Check for free movement of the valves in the case for burrs• ;_._'i: bores. The valves should slide freely of their own 2. Inspect the drive and driven gear bearing surface:. weight in the bores when dry. Inspect oil for scores and check gear teeth for burrs.

-_.: passages in the valve body and governor body 3. Inspect the front oil pump seal for cuts or nicks, :_:_,counterweight for obstructions. All oil passages and the pump bushing for scoring.

must be clean.4. Check the oil passages for obstructions.

3. " Inspectthe matingsurfaces of the governor body.... , _ ._and;governor oil:distributor sleeve,for bur.rsand 5. If any parts are found damaged or worn, replace

distortion. Mating surfaces must be smooth and • the pump as a unit. Minor burrs and scores mayflat. be removed with crocus cloth. --

•,_ 1994 Econoline / F. 150, F-250. F.350/Bronco/F.Super Ou_yPowertrainlOrivetrain Aug 1993

Page 583: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07 -01B -67 Tr anlmlislon, Automatic, C6 07-01B.67BE II

; CLEANINGAND:INSPECTION (Continued)

f, I.... .,.-,..' ",6.: ',-.Check,.thelarge frontoil.pump seal,ring groove,of ', 6. Remove'the rubberreturnhosefrom the• . :.l ";;:::_:;,thepump body:.for,damage..Check,thegasket,,.,: . . remaining steel oil.cooler-tube: , :_,.

• ' I ; " '=mating surface of the,pump body for damage.

• , , . .,,. . _, " . .TRANSMISSION OIL

• " '" ___COOLER TUBES

,- ' Torque Converter and Oil Cooler•, ,,.When internal.wear-or damage has occurred in the

:._.,transmission;_metal partioles;_clutch platematerial, or ,." "" ,..band,materialmcfiy,.havebeen carriedinto the torque ,• : , ,,.,con_er.,ter.a0d transmission oil cooler:These, - -.

• contaminants.are'a_major, cause of recurring•', ,,. transm ssion troubles.and MUST be removed from the ' "

,_,system before:the, transmission:is',put_back,intO.'/' ....:service.

". ./iCAUTION:Whenev.et;a transmission h'as,been ,_: •disassembled toreplaceworn or damaged parts,.or because the'main control valve body valves ro_L___stlckdue to foreign material, the torque "

.... converter and transmission oll cooler. MUST,be .... ;...,,TI ,y--._

"-,. ,cleaned by uslngthe Rotunda TorqueConverter I "

• ,, ,., .. Cleaner,,modelO14-OOO28or,equlvalent.-Under,..:NOcircumstances should an attempt be:made to PRESSURE•• • CONNECTION

,. clean,converters by hand agitation with solvent.Ot 1823-B

..... Backflushlng,and Cleaning Transmission'Oil." , . _ADJUSTMENTS.... .,Cooler,and_.OIl,:Cooler, Tubes .....

:,. 1_ ,,-Conduct backflushing with a RotundaModel . ........ Intermedlate Band _-:..... '" " " "' " "

014:00028 Torque Converter Cleaner or To prevent damage tothe transmission and to assure• equivalent: Test your equipment tomake sure . proper band adjustment;it is essential that thetools

......... that a-vigorous fluidflow is present,before • '.o " and procedures described here are used wheneverproceeding. Replace the system filter if flow is the intermediate band is adjusted.weak or contaminated.

2. To aid in attaching the cleaner to the transmission SPECIAL SERVICE TOOL(S) REQUIREDsteel oil coo_er tubes, connect two additionalrubber hoses to the transmission end of the steel Description Tool Numbertransmission oil cooler tubes as described below. Torque WrenchHandle T71P-77370-H

• Connect the cleanertank pressure_line_to:.the._: Bend Adjustment Torque Wrench Sel T7 tP-7 T370-A

steel transmission cooler,retur, n_tube(IongeSt_,.-;._ 1 " Raise the vehicle on'a hoist and position safety 'tube). ,_'-:_:_-::._': _"__..... _ _-_-_'........ '_":_" " stands under vehicle.

• Connect a tank return hose to the steel 2. Clean all the dirt from the band adjusting screw.transmission cooler pressure tube (shorter Remove and discard Iocknut.tube).. Place the outlet end of this hose in the

• , _ solvent tankreservoir .....• "/, 3. Using Torque Wrench Handle T71P-77370-H• (Part of Band Adjustment Torque Wrench Set3. Turn on solvent,pump and allow thesolvent to T71P-77370-A) install a new Iocknut and tighten

circulate a minimumof 5 minutes (cycling switch the adjusting screw.to 14 N.m (10 ft-lb) torque.onand off willhelp dislodge contaminants in

-' transmission oil.cooler system). " :, i: , 4.. Back off the,adjustlng screwexactly 1-1/2turns,

, 4: Switch off the solvent pump end disconnect the.'solvent pressure hose from the transmission 5. Hold the adjusting screw from turning and tightencooler return tube. the new Iocknut to 48-61 N.m (35-40 ft-lb).

5. Use compressed air:to blow out the transmissionoil cooler or coolers and oil Cooler tubes (blow airinto the transmission cooler return tube) until allsolvent is removed.

1994 Econoline IF. 150_F-25O;F-350/Bronco / F-Super Duty Powertrai_7 OHv-6train Aug 1993_

Page 584: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-68 Transmission; Automatic, C6 07.01B-68III II I1" _' I I

•ADJUSTMENTS(Continued) ....... '.• _ _. .... 1_ .

' i_ " " /

• i , _. _ ,_ _,_._u-

• ,6. : ,Remove, safety stands,andlower,.,, the,vehicle.. " ' "' ' ", ,, C..6 TRANSMISSION '_4" • . _" , _ '. "" !' i.;- ' : ,_ ,

.' :,' _' .... _1_ • .... PARKJNEUTRAL /'i _ "FRONT OF ' POSITION SWITCH / ":

t ; . VEHICLE 7A247 • / "_."_/ AOJUSTING \ \

• :.:, '": 7A178 _ _ k _ CONTROL / ) / \ ILEVER _. / t-... / \

:@:

AOJOSTE.Tg,P-,0_,0-A 1_. i', ,::. _:' / _% RETAINER (PART OFKITT91L.10O_.F/FM) 1_i" BOLTS " /

"' l'_._HANOLE-T'71P-77370-H }• _'_ _, 064,84-8

Vacuum Regulator Valve Operational Checki-_ and Adjustment (7.3L Diesel Engines Only)Park/Neutra'l Position Switch' " NOTE: To check and adjust the vacuum regulator for. _!

:' .. SPECI'AL SERVICE,TOOL(S),REQUIRED,'... proper operation, the engine must not be running.1. Disconnect the two port rubber vacuum

[::' Delcrlption } ToolNumbet t connector from the top of the vacuum regulator • _Gear Position Sensor Adjuster T9 IP.TOO I0-A valve located on the left side of the fuel injection _.;ii

pump.1. Set the vehicle parking brake.

2. Set the transmission in the NEUTRAL position.. . WCUUM.TO................3. With the transmission shift cable properly THROTTLEW,LVECONTROL ,_.

adjusted;loosen the park/neutral position switch O_,PH_AG,',_ ,.

attaching bolts.

NOTE: When performing next step, check to makesure that each leg of the tool is seated in its slot. WCUUM

4. , Insert Gear Position Sensor Adjuster SUPPLY_ -__P,,-_.

T791P-700 IO-A onto the park/neutral position /1_ • VACUUM

•. switch into the three slots provided on the switch _/,_\_.__/,p_,._ _ ;/REGULATOR •"i actuator and terminal plate. :_. _ ._ ,_'k,_ _ i5. r:Leaving the alignment tool in place, tighten the _,:r' . VALVE '_

l attaching boltsto 7-8 N.m (55,75 in-lb). _'_':. /_._,,__1 FUEL• / / __k\"qA_ Yb_<_--/ /1 INJECTION6..:,_!_Removethe alignment tool at this time. / / _(r_,'_"J_(_ --" \\ L__Y" _ /PUMP " 'I_

,,,,Adjustment can be confirmed visually by making ..

_.,,surethe line etched in the actuator and the line _•'_:etched in the housing are in a straight line when ;'.?,_;_the park / neutral position switch is centered in

' ,'!_heutral.

7. !_.Check the operation of the park/neutral position _

?switch. The backup lamps should operate only c"

, >with the transmission selector lever in REVERSE.::'_Thevehicle should start only with the_itr.ansmission selector lever in PARK or . ::.i

' _.:NEUTRAE. . " I

• _" 1994 Econoline/F- 150, F-250, F-3501 Bronco/F-Super Duty Powertrain/Orivetrein Aug 1993

Page 585: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-69 Trsnemiselon, Automatic, C6 07-018-69II III I III

,:ADJUSTMENTS(Continued)

". .... 2:, ,:iRemove,the,:throttlecable from the:throttle lever <:>. 4: Attacha'vacuumpump_and gaUge to theupper,.i,... ,_-,,':._on'the'i'ightsideof,-the,.fuel injection pump:_ 7 ., port-(vacuum,supply,)of the"vacuum regulator

. , , , , . .

' ,3..-, Remove the;tbrottlereturn, spring.'lnstallthe end. valve..,of,the spring over, the throttle lever ball studand 5. • Attache vacuum gauge to the,lowe_po_,,labeled

•'," i _;'the othepend overithe'throttlecable;eupport .... -- -..... ' ' ." TR.AH$ on'the vacuum regulator va!ve.'i bracket. NOTE:_It may,be necessar,y.to continually pump thei..'.

vacuum asJt:bleeds:off:(lhis is-normal).,

' ". ' ' : ; " " . ' . ' . . _'3"_)' ,., .. -: " 6....,Apl_Jy2Oi/lchesminimumofvacuumtothe' .

• • . vacuum:regulator,,valve.and maintain.,Cycle the" . i. throttte_lever,5:t imes from.idle.to:wide-open

, throttle with.vacuum,applied.. "

.L;,; ._ .i_, ,:.. e ,lnserta,O:5;15 inch,,gaugeblockbetween the

" : , block by connecting the throttle cable supportbracket or hold open by hand. "Thevacuum

. , gauge attached to the Iower(TRANS) port-...., ,- should:,indicate,6:Binches,of vacuum.'

___ l <".e_lf;not-_withiq_these,limits,thervacuumreg ulatOr., , -

. i :. ,_valve,mulst_be!r_eadiusted::Adiust,.to:achievea

". . ' :,reading,:of;71.(-t-.,.5) inches,of,vacuumwith20

, , , inches minimum of:vacuum applied. :

'i " ' ' ::;_;"_T,HE_or-rLE:WIOE.OPEN,i :,BALE sruo .

,0,,,,<., "

• -. °' -___kCo)[ '•Item Number .... JDescription

' 1 57620-S Throttle Wide-Open Stop.... Screw (Non-Adiustable) 01Z531-A

L2' -- Lower Port. Transmission.... (Part of9A543) NOTE: During adjustment, do not over-tighten screws

.._........ '. ->3 -- . VacuumRegulator Valve or break the plastic vacuum regulator valve mounting '(Part of 9A543) bosses.

.. ' : . <,. , 4' ' . " ' Upper Port,.Supply Side " '. r : ..... "' 7. " To readjust the vacuum regulator:valve, slightly..' ".. ,(Part'of9A543). .... • ' ' loosen the adjustmentscrews attaching the,5 Throttle'Leve¢Ball Stud vacuum regulator valve to the fuel injection pump.

(Part of9F541) , Continue to apply vacuum. Rotate the vacuum6 Pump Boss (Part of 9A543) ' regulator valve right or.left slightly and note"

• 7 7C47i " Throttle Return Spring gauge.(R epositioned to Hold LeverOpen) • When proper vacuum reading is obtained, 7 (4.

8 9741 Throttle Cable Support .5 inches), tighten the adjustment screws to,Bracket (Locatedon Flat 8-10 N.m (75-90 in-lb). "Surface of PumpBase)

""-" 9 9A543 FuelInjectionPump

1994Econoline/F-150 F-250, F.350/Bronco/F-$u q _ 1 u3

Page 586: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-70 Tranlmlltlon, Automatic, C6 07-01BoTh .

ADJUSTMENTS(Continued) _'_

_ .... • Makesur,evacuum..reading.is. sti Iwlthin .' ; :. '- 10. Apply20 inches minlmumvacuumtothe VacUum_:.. _..,_t,_....:_/-../;i,:ii.:_;:._:._; . specifications,. If the vacuum regulator valve- " ' regulator valve and maintain.Cycle the throttle;_. cannot b_eadjusted to obtain the proper lever from Idleto wide-openthrottle 5 times. At ' "' vacuum;::replacethe vacuum regulator valve curb idle throttle position (not fast idle), the _, ; and repeat the adjustment procedure, vacuumgauge shouldindicateaminimumof 13 ";;:i_ii_ :_

8," Remove t_ie0,515 inch gauge block, inchesvacuum. If less than 13inchesvacuum, the .:_9. ' , Reattach the throttiereturn spring and;thi'0ttie vacuumregulator valve mustbe replaced and the _ :• _;_.,cable securely, adjustmentprocedure repeated. ".:!_._- .,&_' _:. ,._:._ NOTE: Make sure allvacuumlinesare properly '- _'_: ;._t_,_]_:,..... .,,. connected, routed, and notrestricted. , ..: ! . ' __'...._ . :_.._. 11 After final check and adjustment, remove vacuum- . .,,.

gauges and pump. Reattach the vacuum .L • -_,._.'_ connector to the vacuum regulat_ valve properly..,_ :_ :;-;,

.:_;_" 12. Start engineandcheck throtlleTo_erationCheck '_....._:;. :, transmissionfunction. - .-%_, "

',:i',;;SP IFICATIO S

' in ...... :_?, . to ¢. g cnans for transmission., i specifications. "/_.

! CLUTCH SPECIFICATIONS

Clearance

: ' Tranemle =Ion Clutch 4.9L 6.eL 5.8L 7.3L 7,5L mm Inch

,_' Forward Clutch ," ,_

_.;i .',Steal ""_,i . 3' 4" 4' 4' 4 _ -_'":'

:_' " ",'Friction ''r;" _;': :, "W '_"', _",'..3 _-':. 4 4 4 4 0533.1.188 0.021.0.048

," High Clutch

Steal 3* 4° 4° 4" 4' " " '"_.

Friction 3 4 4 4 4 0 558.0 914 0.0_2.0 038 .:.Reverse Clutch

Slael 4_ 5= 5_' 5= 6 = ....

Friction t_ 4 5 5 5 e -- _ '.! "_'

• Plusawaved_plala(ZE457)naxttoinnarpra_lsureplale. ,. "_b Plus a waved plata next Io the piston.

CLUTCH RETAINING RINGS _#_,.' ,- _;;%_.;_._. _ ,,, •

Thlcknat_ " "d; .

. Part Humber mm Inch Front "_*';'" High

,. :_ 377434 1.52.1,42 0.060-0.056 X ;i' '., X .:" ,,__i "

,1;_. 377126 t.75.1.62 0.069"0.08_i_' " X ' :, ..-: ._

:' __. 377127 1.98- 1.87 0.078.0.074 `3 X' X :,

"_ 377128 2.20.2. tO 0.087.0,083 X "._,-', ,..,

' ;_" 377444 2,43.2,33 0.096.0.092 X X

". 386841 2,89-2,79 O, tl4.0, tt0 X ,._'

'_' 386842 3.36-3.25 O. 132-O. 128 X "/'

SELECTIVE THRUST WASHERS (FRONT PUMP SUPPORT) _.,_

Thlcknele

Identification Color mm Inch

Blue 1.42.1.52 0.056-0.060

Naturnl (White) -,- • . 1.85.1,95 0.073.0.077

Red 2,23-2.33 0 068.0.092

! _

-'r_;. _ 1994 Econoline / F- 150, F.250. F-350 / Bronco / F-Super Outy Powertr sin / Oriv etrsin Au Ig 1993 _

Page 587: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-71 Ttanemllilon,Automatic,C6 07-018-71L

SPECIFICATIONS (Continued)•. . •

•CLUTCH BAND APPLICATIONCHART : "* .... -.

- "- - ,.,-. OnoWey Reverie .... " Inletmedlata_ =Goat '_- _FotwitdClutch "" Clutch Clutch .:. :Bend ; -..DltoctClutch-

talGear._lManualLow Applied Applied .,,. • .... , ' u ,

• 2nd'Ge at:--;-2 : Applied .... -",- ,A_plied -

...... '/_ 'lstGear'_' O " -'Ap_}liod Hold,ng " " " " " " : " -.

_.,.: ;2;_dGear--D -Appliecl ...... ; -_.-.,,.,__:,_._',.Applied.....:- .;':

':'_/?:"': 3rdGe'a(=-_O _ "..... - - Applied ... Applied

Re,._er_'e"(R)"'''':_....".... _ ..Applied _ .. -...... _, Applied

CONVERTER END PLAY

....... _" ' _ ra " .... :" Torque Converter End Play J

"New or_i_ebuiit Torq ue_Con'_ertet .'r , Ueed Torque Converter 1mm Inch mm Inch

0.533_,ta_ 0021Max 101 Ma_ 0040Max.

........ ....... /; • L'; 'OtL CAPACITY

. . _ :Approximate.Refill Capacity"

Tranemlulon U.S. ..':Imperial

Vehicle Type " Engine ,-Quarts .L >Quarto" " Liters

E; 150 _ E.250 -- E.350 C6" _ 9L (300 CIO) I-6 12 9 8 1 1.4

5,8L (35 1DO) v.8

.- , 7.SL.(460'CIO) V-6 .... : - -" ....... '"7.3L D,e"=el

":1_;t-50(4,¢2) ` ' ' C6 '= / 4.OL(30OCID) I6 ',:12:0 ." _10. 0 ...,: .... _1.1.4;,

F.250'--:-F:350(.I,_2) " C6" 4 9L (300 CtO) I.6 12 9 6 '.l 1.45 0L (302 CID) V-8 '

5 8L (35 1CID).V.8

7.5L (460 CIO) V.8 ..7.3L Die _el

F-250 _ F-350 (4,t4) C6 _ 5 8L (35 ! ClO) V-8 135 " 10.8 12 8

7 5L (460 CIO) V.8

'a Appro,dmatedrycapaclty, include'Stran'tmis_,ono*lcooI.at andl,nel Od level indicator should be u'sed to determ;ne actual oilrequ;rement_ando,lspec*f;cahon'l Check level at normal operat,ng temperature OONOTOVERFiLL

b Use MolorCraft MERCON DMulti.Purpose Transmission Flu;d E4AZ. 19582.B (ESP-M2C 166.H).

. .;':_.,_ ,,". ..... ....,.VACUUM,DIAPHRAGM=ASSEMBLY SPECIFICATION "

Th_'ottle Control Valve Rod '

Tranemle=lon Diaphragm Diaphragm'. . " PartNo.

• Type Type PartNo. '"_ _ Identification (7A380) ' Length Identification

;" , C6 . : HAD _'-. DTAP.TA337.AA PartNo. Stamped C4AP.A 1•677.1.667 NoCoIor

' :: C6 ;.. SAD. 070P-TA377-BA = I Green'Stripe OlAP-BA 1.727-1.71/' Purple Daub-

" C6 SAD- D4TP.TA377.BA ... 1BlackStripa . O3AP.OA ' 1.611.1.601 YellowDaub

C6 SAD D5AP.ZA377..AA 1 PurpleStripe D3AP-EA , 1.644.1.634 ,- . BlueOaub

.... ' D3AP.FA 1.660.1.650 Green Daub

• _'.. D3AP-GA 1.710-1.700 White DaubOBAP.AA 1.694.1.684 Brown Daub '

• :. . a Selective lit.throttle control valve rods.

SAD'_ Single,Area Diaphragm :," .HAD _ High Altitude Diaphragm

1994 Econolina/F-150 F-250. F-350/Bronco/F.Super Duty PowerttainlOrivetr,,;n Auo 1993

Page 588: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-72 Tranirnlsllon, Automatic,C6 07-018-72II I "_"

SPECIFICATIONS (Continued) ,. , '"

; _' f.° r ..

_.:'.CHECKSANOADJUSTMENTS. ,'.. • CHECK;S AND ADJUSTMENTS (C0nt.d) .. :. . .,,,... .:,. .

Operation _ Specification Operation Specification

i t;•Tf nsmis$ion EndiPlay 0.203- t. 1tTmm (0.008-0.044 Inch) Selection Retaining t.42. t.52mm (0.056.0 060 Inch) '; :_._,:. ._.,,_:

(Selective Thrust Wa'_hets Ring Thickness t,62, I. 75am (Q064-0,069 inch) _ , ,:_:_,._ , Available) 1.67.1.98mm (0014.0.078 Inch) :'_

Lo:'wandlnletmediate_ _ =,,Remove and discardlocknut:lnstall 2.10-2 20mm (0 083-0 0871nch) ;!:_Band Adiustment new [ocknut. Adiust screw to i 4 H.m 2.33.2.43mm (0.092:0096 Inch)

(tO ft-lb) lorque, then back off 1.112 2.Tg-2.89mm(0 110-0 114Inch) "'.: ,..,,

turns Hold screw and lighten Iocknut 3.25 ;335mm (0 ,28.0. 132 Inch) _ i!'!!_I'

to 54 N.m (40 tt.lb). Reverse Clutch 0 558-0 914am (0.022.0036 Inch) _'

Fc:onl Clutch Pres:_.ure 0.533- t. 188am (0.02 t .0 046 Inch) Pressure . ;o ,plale.to.Relaining Ring Plate-to.Retaining Ring _.__.Clearance .: Clearance -

. (C_ontinued) Selective Retaining t. 42- t.52mm (0;_056:0.060 Inch) ,. := ": Ring Thickne'_,_ 1.82.1.75am (0_064.0 089 Inch) "

, - 1.87- 1.98mm (0::0"74.0,078 Inch)

'"_ 2.10.2 20ram (0 083-0.087 Inch)2.33.2 43am (0 092.0 097 Inch)

i': _' "" STALL SPEED

% . !_:"..... "_:,=:__ Stall Speed

';i " '_': Engine Torque Converter

!,. VehiCle Application Displacement Sl=e MIn. Max.

F-:,t50/E- 1501E.250 Van 8850,¢ OVW 4.9L EFI 12 Inch 1622 190/'

H0'F.250/F.350 4 9L EFI 12 Inch 1580 1855

E:350 4 9L EFI 12 Inch t580 1855

LE) E.250 Van 4 9L EFI 12 Inch 1622 1907

HO F.250/F.350 5 8L EFI 12 Inch 227 I 2655

HO F-2501 F.350 75L EFI 12 Inch t983 2315F:'350 / E-350 L" :; '

7:3L O,e_el 12 Inch t825 2008

LINEPRESSURE ''_

15-17 Inch Hg 10 Inch Hg Vac. O.S Inch Hg Vac.

Transmission Model Range Vac. (Idle) (Part Throttle) (WOT Stall)

__ _All_4 9.L and 5_8Lr_t_YxiCO.= .0, 2,--I ........ 50.60 - 90- 115 - 160_190 " - .:. :-" "-.:': '-

R 65. t 25 t 40.170 250,280 :,.P. N 50-80 ' -- --

All 50L and 58L O. 2, I 50.65 75. t00 155- 185

R 60-95 120. 150 245.275P, N 50-65 -- : --

All 7.5L O, 2. 1 55.95 100.120 165- 190

R 85- 145 160. 185 250-280

P. N 55-95 -- --

All 7.3L Oie3el O, 2, 1. R, P, N 50-62 95- 115: t65; 190

,_,.,!_ . 60- 120 140. t 70, ." 250-280 ._

'.,;',. 50-80 . ::.

h

, LINE PRESSURE (HIGH ALTITUDE APPLICATIONS) LINE PRESSURE (SEA LEVEL) ._,_

24'_5 Inch 29.5 Inch :_';';

A_, =_'olute 15-17 Abaolute 15-17

Barometric Inch 10 Inch Barometric Inch 10 Inch ::i;:_:,_Pre=iure (st Hg. Vec Hg. Pert .5 Inch Hg, Pressure(at Hg. V_c Hg. Part .51nch Hg. '

5000 Ft.) Range Idle Throttle WOT Stall See Level) Range Idle Throttle WOT Stall '

All With High D, 2, I 50-65 60- I00 130-170 All With High D, 2, 1 50-85 85.120 150-190Alliiude R 60-95 100- 150 205.255 Altitude R, 60- t35 135- t60 230-280

; Vacu'u'm'" P, N ' 50.65- _ _ Vacuum P, N 50-85 _ -- ,, ..Tht,0tlle Throltle ,.-Valve. Valve "-"

OialS_agm.,,_ _Oiaphragm _" " ":

(Aneroid) (Aneroid)

_ .. 1994 EconolinelF.150, F.250. F.3501BroncolF.Super Out,i Powerttain/Orivetra;n Aug 1993

Page 589: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-O18-73 Ttanemlsslon, Automatic, C6 ,, 07-018-73 _I II

SPECIFICATIONS (Continued)

• -o,Z, ..... _ . , .

"".:.i:; " ;Shltt_Speeds_;' _ ..... ,

- . "_-'4.gL_'SHIFT_SPEEOS _ ACTUAL MPHE-150"_"/AXEE RATIOS_2L73;_3:08'_ "

..... " " LowLImlt HlghLImit .

- - ,Throttle Opening" Drive Range ' Shill " '_ . ' MPH" ..... MPH _

- Minimum Throttle • O 2.3 9 24,

,Closed Throttle O 3- I 6 tO

"'CIo_edThrottle" " t 2.1 - ", 20 .... " ' ' 32

" Part,Thrr)ttle(toOeten,) _ ." " O " 1.2 -i /.22-" 41

. Part Throttle (to Detent): D i" "2-3 .',i37 _-_ - 63

- Ma_ Oownshift(toOetent)-.,,_ .................................. "''-O'_°_'. °. " ....... . '" ...3:2 " : _ "":26": "' " " 54,Wide Open Throttle.(WOT). _ 'ff"_" ": _- '-" "'_O t .2 3 t 42

Wide Open Throttle (WOl_)" .... . .- " • O " 2-3 54 68

Ma_. Oownshitt (WOT) O 3.2 47 60

Ma_ Oownshitt [WOT) O 3.1 20 30

,' : ,_'.4,9L :--;SITIIFT_SPEEDS'--:-,AC1 LIAL',MPH E: AND F-SERIES(-150'/_250,3!50)_Z_-_AXI_E'RATIOS,3_54;3:55',_3:7 3 4.10

_?'Low Limit ... _:High L mltThrottle Opening "- Drive Range Shift - _: "'-:_._..:_M_H,,, .... " "' MPH

M,nimum ThroHle O 1,2 6 t3

M,nimum Throttle O 2.3 6 22

Clo _ted ThtoHla O 3-t 6 8

CIo_,ed Throttle . • 1 2. t t6 30

Part Throttle (¢O Detent) O t.2 t9 36

Part.Throttle (¢oOetent). ..' O _2.3 , :i:32 , ' .'54

M.l,_,,Oown_hitt (to Detent) • O 3-2 "r '" : 2 5 ........ ; i " " " 4 8

W_de Open Throttle (WOT) O t.2 30 40

Wide Open Throttle(WOT)' O ' " 2.3 5t 66

Max Down_hift (WOT) O 3"2 ' 47 62

Max. Oown3hitt (WOT) D 3.1 20 3 I

5.8L m. SHIFT SPEEDS_ ACTUALMPHFoSERIES(250/350)_ AXLE RATIOS3.55,4.10

Low Limit High LimitThrottle Opening Drive Range Shift MPH MPH

M_nimum Throttle O 1.2 6 t6

M,nimum Throttle O 2.3 9 23

Closed Throttle D 3-1 6 8

CIo_ed Throttle t 2- t 23 36

Part Throttle (to Detent) O t.2 25 44

Part Throttle (to Detent) O 2-3 4 1 69

x.: Oownshift (to Detent) " D 3-2 28 • 57

Wide Open Throttle(WOT). ,_ . O ' 1.2 34 - 47

Wide Open Throttle(WOT) O 2.3 59 74

• .Max, Oownshitt (WOT) :' O 3.2 50 65

Max.'Oownshift (WET) • '. O. ' 3-1 ' 22 " 34

,. ; 7.5L_.SHIFTSPEED_ _ ACTUALMPHFSERIES (250/350) _ AXLERATIOS3.54, 3.55, 4.10

_'" "" " ' Low Limit High Limit

Throttle Opening , Drive Range ,_ _ Shift ' MPH MPH

Jinimum Throttle D t-2 6 16

Minimum Throttle D 2-3 9 26

Closed Throttle , O 3-1 6 8

Closed Throttle 1 2- 1 22 34

Part Throttle (to Detent) O 1-2 26 45

•- Pert Throttle (to Detent) O 2-3 45 70

(Continued)

Page 590: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-74 Transmlselon, Automatic, C6 07-01 B-74•_ II I II I I

SPECIFICATIONS (Continued) "

.j, . •

• L7.5L,r_SHIFT, SPEEDS,mA_CTUALMPHFSERIES(250/350) ,_-;AxLERATIOS3.54,3.55,4,t0(Cont'd) .... _ -" :':' ,::_,_.:, t _':

__;._ 'r LOW Limit High Limit '" '::'

i'ir Throttt_,Openln 9 Drive Range Shift MPH' MPH _. .

;.Ma.x.Oownshitt (t_,Oetenl) O 3.2 25 . 48 ..,::;:.; ;,,_

Wi.de Open Thiottle (WET) D 1.2 34 48 " :::_; " ;:"

_Wi_deOpenThtotd;e(WOT), O 2.3 80 ZS "i_ '::_Max. Oownshitt (weT) O 3-2 50 87 ,.'- '_:,_

_" 7,_LDIESEL -- SHIFT SPEEDSm ACTUALMPHE"ANDF-SERIES(350) -- AXLERATIO4.10 ......._;,

':i "4!il Low Limit High Limit ....

' "} Thr ot tl_:!_Opanln g Drive Range Shift MPH ...... MPH , ;,_.:

:M_nimum Throttle'"" D 1.2 6 "_"(';"_'_'_•" 7

_Mi_imum Throttle O 2.3 t I ,, ;.},_. 16;!Cl_)sed Throttle O 3- I 6 7

Clbsed Throttle t 2.1. 12 18

Pat, t Throttle (To Detent) O t.2 19 26

Pa?t Throttle (To O:etent) O 2.3 3.5 43

M_. Oownshitt (To Detent) O 3.2 29 38

vv,:deOpen Throttle (WOT) D 1.2 24 28 ....

W_de Open Thro_il_e (WET) O 2-3 42 47

' kt,_ ,LDownshitl (WET) D 3-2 39 44

Me,( Oownshltt (VET) O 3.1 15 20

' ; TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS(Cont'd)

o.,cr'_'pt_o,_ _.,_" L_.rt -I De,_,Ip_lo, Nm Lb-Ft

Torque Converter to FIywheel 28.45 20.34 O,IFiller Tube to Engine (Econohne 32-47 24.35/.3L) "_

Torque Converter Ora,n Plug II-3;* 8-2/'Transmission to Engine 55.67 40-50

Front Od Pump to Transmission 22-40 16.30 (Gas Engines)C a 3e i - -' ::

-O_-e-rrun'ning-Clutch-R&CetSC_-_-@ - 25.33 18.25 " ThrottlePre'tsure-_PlugCase " 9.16 " (-;'9.14I-In.Lb)

Tran 3m,_sion O,I Pan tO Case t I.16 8" 12 Front and Rear Transmission Oil 25-32 18.23

Front Pump Support to Pump t T-21 12- t_ Cooler Line Connector to Case5/ 161nchFdhng(Case Fitting) ....

Converter Cover to Converter 17.21 12-16

Housing (All Except 7.5L) Cooler Line to Transfer Case 17_;24. 12.18

Guide Plate to Ca_e 1T-2 t 12- 16 Filling 5/ 16 Inch Tube Nut

Transmis sion.to-Eng_ne (Diesel 68:8'8:" 50-65Intermediate Serve Cover to Case 10- 16 14.22 ,,

Engine)4

Oil Oistributor Sleeve to Case 17-21 12.16 SlartetBolts(OasEngines) 54-68 ' 40.:.50 '_' "' CE_ter_!sion Housing Assembly to 34-47 25.35 :_#_'. ::

Transmission Ca se St_ar'ter. Bolts (Diesel Engines) '- 68-88 50-65.'Transmission Insulator-to-Frame 96- 128 10-94

Case'Front Pump or Line Pressure 8.5.16 6- 12._ Nuts. F-Series

Plug!.!• "' Transmission 8 t. 108 60-80

Pr assure Gauge Tap 8.5-16 6- 12 Insulator-to-Extension Housln9

Band!iAdjust;ng Screw Locknut to 48.61 35-45 Bolts, F.Series "

Case ; Transmission Insulator-to-Frame 68-94 50-70

Torque Converter Drain Plug 11-37 8-28 Nuts, E-Series

Manual Shift Valve Inner Lever to 51.54 30-40 Transmission 68-94 50-70 .

Sh a'ft:" Insu_ator-to-Ext en sion Housing

Oownshit't Detent Lever to Shaft 17-2 t 12-16 Bolts. E-SeTtee

Oil Fil!er Tube to Engine (Econoline 54.67 40-50 Vacuum Throttle Valve 16-22 12-18• Oiaphragm/Heat Shield-to-Case

5,8_).., ,, Bolt ';,Oil Filter Tube to Engine (Econolina 44.56 33.42 _

4,9L). Governor Oi| Co_ector Body t8,22 12-16

(Cor;,tinued) (Continued)

'" 1994 Econoline/F-150, F.250, F.350/Bronco/F.Super Duty Powertrsin I Orivetriin Aug 1993

Page 591: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01B-75 Ttansmllelon, Automatic, C61 . 07-01B-75J I I I • I III I

SPECIFICATIONS(Continued)

_ ,: _::.:,_';::-. ,'':TORQ.UE_SP,ECIFICATIONS,(C'0nVd):...... ' , :.: •. TORQUESPECIFICATIONS (Cont_d)'_....

."." " i" Oeictlptlon '." H.m-. " Lb-Ft i.:., :_ ,,;..;Oele,_dption : ..... "., _ ." N_m; - Lb-Ft. . . - . ,

, Cro_lsmreml3er.to.S;deF_'ameRa,ls 58-77 ' '43.57 Upperfo_Lowei"MainControIVal;e, ._ 5.6 2 .... - '40-55m i

Sh#ftVatvePlatetoMainConttol'_ ' 3-5 " ._ 27-44 .;. Body . ..

• :'Val,_e Body (2] " . " , Re,ntofcing.R,gh'l.Sidepla!eto .._ , .'," [,3.,5-,:., . ,- 2,7.44 .-.... _ ...... Lower.K,1'a'in..Control.,Val,_e Bod,/- ," .... :

• _.,: .-'Boo_rValve Prate to Main.Cdnttol " ", , 3-4 ' ". 27-35,. ' . ......

',:,,'_;'_ II'Val'_'eB°dy(6) ; i" ., . " . . " " . ..... %: _ ,, . TorqueC0nvlerterHouslng.Covert0-' ,.'_ .:_,.7,:'; '.'. 35.54 ?

J;fnne/Oowns_itl:Oetent.Le'verStop::.'l ': :'2.'5_5 " ' : _20-45'. " C°nvertetH0usihgf:(Z:SL').. • ..'", ,.- .- ";':'.': "'".. I,'j "" ...':: "" " " " "

j ....

,,:; ...... . , , . . _ _M] n.ContfoI,ValveBod}lAss'e'mt)l¥ ,; ::'?,!:t l':t4;: -._95-'125'.

" ""_" " ""'_" 'Remf°tcem_entPlatet°'B°(:lY"Control-,Scteen.t,"' _ :2.5:55.,62'L.' '"'20.45.,40.55. -'. -toCaqe: :., %".-..:.r.., . /_;,._, , :.. . :. :.....'; '

and:Lower to Upper,Main Control ' " ' _Coltector.,.Body,.''G°vetn°r'BOdY:t°G°vern°fOJ':.'_.._. ,,.-., _: :'. "", ,,"" ";-.,:,.',_t_l_-_t3o .--,:' , : '.'97'-. t 15

'" ' .... '_ .'Shift Valve.Plata tO Up'-_:ilam.',p.,.,,, _: .... 25_5 ' . 20;45. Manual,Valve Orient Lever Spring 95-:13.5 B0. t20

Control Valve 8ody to Ca'_eManual Valve Oetent Lever 65.8 55.75_q

_Continued; Park _/Neutral Position Switch to

.Case

, _,..... ',To r qu e Limit s;:Tr an smls_lon Oil Cooler.:Tube_Eltt_ngs ,

' t'"_'[ "_ , _ ad,a,o/. -.. -,Tfafl$ l_'s 1_'C)P, •J..":'. .... ' /- _:" ,_ ;i;iOi' CGo"r'Tube'.u,.. . _ " ' ,Transmission ' N.m , F't,Lb N.m " ' "'".FI:-Lb " 'N.m .. " gt.Lb

t t.t_ 8. t2 z_J, "..,azJ .. t_.2_ ._ . ,2. t_c6I'/

_/SPECIAE SERVICE_OOESTEQUIPMENT ' ....

-.Tool Number/ • TooINumber'?

Description illustration : Oesc/Iptton Htusttahon

TSOT- tOO.A TOOL.70OO.C)O

ImpaCt SI,de Hammer _tsa,.,o_m R'ubber T,p For A,r Notzte

TSgL. 1008 roo,.._o_m go

Impact Shde Hammer (.._......__.,,;,._.......__.._ -TOOL.ZOOO'OE

t_.._Oc-& A_r Floozie Assembly

. ._._._., ,,.-_.Puller Attachment ....... '

TO,Ot.. _'0Oq-OlE

• " T66L.7003"C2 ,

TSFL-500.8 _ .Front Pump Bushing Replacer

Ben'ch Mounted Holding Fixture , '

t S4k.TO03.C_f $tL-!_41 .

• T6 tL.7657-B

'TOOL-tIT5'AC . . Extension Housing Seal . '" _'•,SeaIRemover '_, ', " _ F_eplacer

T77L.7697.C

Toot._-_c . Extension Housing Bushing

TOOL-420 'i.C _• ReplacerOial Indicator with Bracketry ,L_[_II,,F._

T/TL.Tttt-C

o .-. ., (Conhnued)TO_t_.42Q I -_

(Continued)

Page 592: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-01 B-76 Transmisllon, Automatic, C6 • 07-01B-76I III I I Jl

SPECIAL SERVICE TOOLS/EQUIPMENT .... _

(Continued)

%" "ToolNumber/.' .... " " ' ToolNumbe¢/ ":"-

•,;_,:, Oescrlpt!on Illustration Description Illustration , _,_,

TT:_L'7697.O '_;" T83L'7902.A ',_'_. •

Ex"en s'°n H°u'!nq;Bu sh'ngRemover_, . , _ Converter Checking Tool Kil _r-"-"_t' _' .- '<'i'A.";i;_,,:,,, :'_

, _:_ ,.,. trtt..r=l,o ; ,'_'_:;,,, f ,_,

TO L. 77288 "_,_, T*=L._r_.A , _,' ,_" . , ':;J"

SHi')I Lever Seal-I_ie'placer ,..;;:-.. ,

: ." ' '_; _ Ta0L-77030-8 _ .- _,:

!' '" Servo P_slon Remover :, '_ .... ' .c, .Q/ ..

'i. _' TOOL.??lll '_

"lq_'p:d Adlu_lment Torque,_3tench Set _._ _'-"_ T9 1P.700 IO.A

l

/._ ..- (PartolK,ITglL-1000-F/FM) _ _---- "_

T65L- 775 15-A .-" r _,,,._o,_,o-,,

Clutch Spnng Cor;np'ressor _ i':-_.:_ ' " "_''_ T92r./B2OO.AHI:_' " _ :::=%'_=_''T_"U VRV Selling Gauge Block

@';}i ' ," r 4 'IL"'_?'_I 'I" 'I'

Tl'_L.T1548.A " r_ r.r_c_. ,H

L=p. Seal Protector ':

','-' ROTUNDA EQUIPMENT '"

• "' Tool Number Description

0 14.00 I06 Encjme / Transmission Stand

T87L.t7837-AH ' ' ?'

Front Pump Seal Replacer 0! 1.000 _9 Tran'sm.s.';,on JacX

_k___ ........... 0 14.00028 Torque) Converler Cleaner021.0005.! . .- To{queCon,_erlerLeakTester. " - --. '......

TI/L.FTI*Jt At_ 014"00737 Aulomal_c Transm_3.3_on Tesler

", 021.0(30 14 Vacuum TesterT69L-TOO,14.8

Clutch Housing Bushing Tool ,, _ 059.00008 Vacuum and Pressure Teller

,,,_.,oo,,., PARTS CROSS-REFERENCE .......'..........

T 76L-7902-C

Converter Clulch Torquing Tool

BalePatltt ParlName Old Part Nam_ . ,

t 2A650 Powerlrain Control

Module

4602 Oriveshatt

_z_L.:,_zc 60 10 Cylinder Block

T77LL7902.R f._ 6068 Rear Engine Support

Converter Clutch Holding Tool /_ In3ulator

6096 Rear Engine Support

Bracket

Tr_L.t_-_ 6303 Crankshaft

T80L-7902-A 6375 Flywheel

Torque Converter End Play _./ 6582 Valve Cover

Checking Tool __*t :__-_..._ PoA023 Rear ,n_ine Support SuQpOrt7005 Case '.TIOL.71_Z-& " '"

70 17 Input Shaft

(Continued) "(Continued)

1994 Econohne/F. 150. F.250. F-350/Bronco_F.Super Duly Powedrain/Orivetrain Aun 199:3

Page 593: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

07-018-77 Transmission,Automatic,C6 07-0 IB-77I I I I

PARTS CROSS,REFERENCE (Continued)

'8_'t_,Part.lt ..... " ,,-_PirtN=me '. 4- ,.S.:.Oli:lPJttN,im e 8ateP=d# P_ilN,Ime : .OldPartN4mQ':

";7034 _ .Vent"=' .. i .. _, _,. ':'. .:1816 4_.:._..".Revet_leCl'ulCl_ ;'.'/"_ • ..... _....

;7660i": Ouipul Shall 78258 , 'FxonlO,I.PumpBu_b_nq !-.... "...i . ,

7086 .... Extension Housing 18488" ' 0,te'ctClutchP,,_ton

Ga skel.. :Spring

"7902 .... ,.'..Torque!C'on,_erler , ' Torque Can_eclo_ !.... 7C09g -'O,rect Clulc_ Inner Seal

,'. 797,6.'_. ,Conve,'Li'erHoOmng..: . '.:"'.. *.. 7C232 _- 0,1O,s nl3u'orSleev=J_ .I "i'" .' .i" '

I._YAOQB:I .,Valve. Bocly;Separahng,, . . . , ". .... 7001,4.: " .'Thrusl_Wa:sner. ' '.'.L': ..,,Plate'. "" '

: ._ :, .' " .,, -. ': ..7002"1 _ 'lnlerrned,ate'Band . ..

• _7A020 _: OdLevel_lndic:ator , , . - i, ,.Se_:vo,Pl'_'lon

• 'YAO_3i'' O,ICoole,.Tube " . 7.0026... ,_Ser..vo_Pislon.Govet. •

' , ,,,,•,. 7A034, .)-Extension.HousingS. ,I ....... " " i " ' , .Seal "" .. ,, : ....Bushin 9 .:70028: S_r'ao :P._slo,_ Spring'.

7A039 Exten']_on Hou_in o..... _ ' _ 70044. Rever_e ClutCh Orum

7A089 One ._l..ly ClutCh 70066" Inpul Snell Th,'u'_lV'lalner

7.AQ')5 Tran_lm,sS_on Od Cooh.}r , . .......• ' 7.0070 ,_, Rar.kmo_P'a:.,A:R,.':lutn ........ ;' _" ""

7A I(30 Ma,n Con{,'olValve Sptm 0

E}ody . <7007 I" _ ,'Park,rio Pa_lS_a t7A.Io3.. Front Pump Supporl

and Gear 70080 Thr.ollhl.Control "V:_I_o

.'?'AIOt] ' Front Pump SuppO,'l 70164. .,Oulpul;SnallHub

7Al,36. • O,lPuml3"C,a'_ke! ' ' : . 170111-'/ :.One:W,3y'.ClulCn:R'ace

-' 7A 153 . Rm(] G,}.'l," i "10'22.0. r , .GOv.'._rnor:O,I;ColleclOt , -

7A 178 AClji_ijt,rlg SC£f)w !_'3rJ'It !

• -7._ t:}.l Tr an'_m_,'_on Od Pan . 70:t 14 'Parking] Flod:Supporl• Pl3to ' -"r

• 7A221] Od Fill,h" Tube 7F_.085 _q,z,ar Clutch P_'e'_'_ure

tA2,1t Park ,'lq,+),alral PO'3)hOr', l'loutral Sw,Ich Sor)n_

Sw,tch 7E38? Tran 3nm'_'_,on Ma,n

7A 24_'J Fronl 0,1 Pump Seal Control Sc.re,._n

TA362 Clutch P_sh]n 7E3')5 rrant, m,3"_,on Sh,R

7A 3PJO [hrollh) Control Valve " Cable and Bracket

Fq,_,d /FOO6 Vacuum D,aohra0m Cho

7A.t4l Parking Pawl 8005 Rad,ator '

7A521 Clutch P)ston Spring 9E926 Throttle Body

Retaiqer ............ --"'"l""" ' _ " . ....

/_066 Clulch Pressure Pla_e, ' '

(Cont,nued) .............. -, _" ",.....

F fence/F S t t1994EconolinelF. lSo, F.250. .350.'B • uoe Ou vPowettr;_int(3rzw_LtrainAuO 1993

Page 594: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

ROCKWELL TA TYPAXLE .........

MAINTENANCINSTRUCTIONS

Page 595: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• :,R@GKWELL,.:T,'A,T.YPE:AXLE •., , - " • •

AXLE SHAFT REMOVAL

1. Place a drip pan under the end of the axle.

2. Remove seal and bearing retainer (item 34) from the end of the axle housing.

•. 3. Pull the axle shaft (item 26 or 27) straight out and the. tapered roller bearings will come with it.

_,. 4. Remove bearing cup from the housing if new bearings are to beinstal,led.

AXLE WHEEL BEARINGS REPLACEMENT

1. Using a suitable press and puller, press the tapered rollerbearing cones off the axle shaft.

2. Press the new bearings onto the axle shaft with the largerdiameters toward each other.

3. Thoroughly grease the bearing cones with wheel bearing grease.

4. Insert and seat a new bearing cup into the housing recess and•, grease.

AXLE SHAFT REPLACEMENT

..... -1_ - (3t_ecl<that tt_e inner bearing o-up-is installedand-seated in ..... - " -the housing and greased.

2. Insert the axle shaft into the housing.

3. Grease and install the outer-bearing cup.

4. Install shim pack and retainer, secure with screws (item 36),torque to 50 ft. Ibs.

5. Check for end play. Add or-remove shims until there is no or"0" end play. Then remove a .003" shim to obtain .003"preload.

6. Apply sealer to inside of retainer after final shim pack hasbeen determined. Assembly retainer to housing and installscrews. Torque screws at 50 ft. Ibs.

Page 596: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' .,,; -..... : . ." ".. " ". ,,.: -:R@QKWELL,':_TA,-I:YPE AXLE"., .....

REAR DRIVE AXLE ASSEMBLY

A@@. \ \'\ \"/

I

I

II

II

- I

i

2

Page 597: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' R:C):G:KWEU"::.,:T,-'A_RE AXLE .

REDUOTION GEAR BOX - REAR AXLE-

3

Page 598: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.:.... - -. ' .:": ROQKWELL ,TA TYPE AXLE. '• . ,., , ,. ,

DROP BOX REDUCTION GEAR REPLACEMENT

1. Place drain pan under the axle.and drain the lube oil from

., _..,:,.,.;. '.:,___:,,...'...-:..:,::.::;:both:_,the::cer_ter_:housing,.:and,.!the:drop box housing :.,.:: ..

2. Remove input flange (item 67) retain nut cotter key (item 65),nut (item 65A), washer (item 66) and input flange (item 67).

3. Remove back side bearing retainer (item 85) and. screws (item 87).

4. Remove snap ring from outer bearing diameter (item 77).

5. Remove reduction gear box cover bolts (items 88, 89 & 90) andcover (item 58).

6. Remove input shaft with gear (item 76), and bearings.

7. From the large gear shaft, bend up tabs on look washer (item64), remove the Iocknut (item 63), lock washer, (item 64) andnut, (item 63).

8 . Remove the gear (item 61). If it will not slide off, use (2)jack screws, 1/2-13 x 1 1/4" long into the two tapped holes inthe gear to remove the gear with a gear puller.

9. Clean the drop box housing and replace the drain plugs

10. Place the new large gear (item 61) on the shaft and tap on toseat.

11. Install nut (item 63) and torque to 500 ft. Ibs. Installlock washer (item 64).

12. Install Iocknut (item 63) and torque to 500 ft. Ibs. Bendover tabs to look both nuts.

13. Install new bearings (items 75 & 77), as required on the inputshaft with gear (item 76).

14. Install new input shaft and bearing assembly. Remove snapring from the bearing, (item 77) if the bearing was changed.

15. Assemble cover (item 58) with new gasket (item 79), screws(item 88), lock washers (item 89), nuts (item 90). Torque.bolts to 50 ft. Ibs.

4

Page 599: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

' • " ".... .:!_RQC;KWE,BE:,TA.:_PEIAXLE:

16. nstall snap ring (item-78 on the end of the _nput shaft withgear (item 76) if the snap ring was removed to replace thebearing, (item 77).

,.1:.7.... I.r_stall_:the.,sr_ap:.r.ir_g:.into:,t-he..':bear,.ir_g:'.(iter_,.77).., • ,.. '. .... .

18. Using a new gasket (item 84), install the rear bearingretainer (item 85), with the four. screws and lock washers

• (items 87 & 72). Torque to 50 ft. Ibs.

' 19. Install the input flange (item 67), lock washer (item 66) and.:.. nut (item 65A). Torque to 200 ft. Ibs.

,.. 20. Refill with GL-5 axle lube 85W/140, 80W/1 40 or 75W/140 to':' ..... ,- bottom of carrier fill plug and drop box fill plug. 1 0 quarts

_. required.

5

Page 600: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

:. .... _..,..,.. ; :.: _/ROCtKWELI. TA-;TYPE.AXLE... :."..... : , ..t

DIFFERENTIAL REPAIR, PINION AND RING GEAR REPLACEMENT

1. Jack up the vehicle at both ends and put on secure jackstands.

2. Remove the rear wheels and tires.

3. Drain the rear axle lube oil.

4. Remove the 4 bolts securing-the drive shaft to the axle inputflange and move drive shaft away.

5. Disconnect the 2 brake lines at the brake tees.

: 6. Place asecure jack underthe axle and chain it to the jackfor your safety.

7. Remove bolts or "U" bolts securing the axle to the spring ormount bars.

8. Lower the axle and move out from under the vehicle.

9. Place the axle in a clean work area on a bench or clean floor.

Break brake line at tee for separating axle halves.

10. Remove back side bearing retainer (item 85) and screws item 87).

11. Remove snap ring from outer bearing diameter (item 77)

12. Remove reduction gear box cover bolts (items 88, 89 & 90) andcover (item 58).

13. From the large gear shaft, bend up tabs on lock washer (item64), remove the Iocknut (item 63), lock washer (item 64), andnut ( item 6 3 ).

14. Remove the gear (item 61). If it will not slide off, use (2)screws 1/2-13 x 1 1/4" long into the two tapped holes in thegear to remove the gear with a gear puller.

15. Remove nuts (item 60) and lock washers (item $9) securing thecase half (item 58) to the axle carrier.

16. Remove bolts (items 19, 20 & 21) securing the two housings ,.(items 1 3 & 16) together and separate.

6

Page 601: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

AXLE " '.......... - :.:/:iRO:©:KWE,EE,:T,A__PE: :

17. Remove the differential and gear assembly.18. Remove bearing retainer (item 51 ).19. Remove pinion shaft item 5 ,.with bearings.

t.

7

Page 602: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

. ._., _., _, L ,__' , • - :, , . ,-. • ,:,, ' ". " ,: ,."...' . :.:-R©CKWE:'LL:!TA-_PE'AXLE ' . ..... . ', , '. ,,.

DISASSEMBLE DRIVE UNIT

: DISASSEMBLE DIFFERENTIAL REMOVE GEAR RIVETS:AND GEAR ASSEMBLY

I J I

RIGHT

!\ \.'_ k'1

A. If original identification marksare not clear, mark differentialcase halves with a punch orchisel (as shown in photographabove) before disassembling, for

correct alignment when reassembling. _,

wire, remove boltsor cap __

B. Cut lock

screws and separate case halves. _ ____ _ __._C. Remove spider, pinions, side gears ' -- - -

and thrust washers, if." .': -?

D. Remove rivets and separate gearand case if required.

1. Carefully centerpunch rivets incenter of head.

2. Use drill 1/32" smaller than bodyof rivet to drill through head.

3. Press out rivets. E. Remove differential

bearings with bearingpuller if necessary toreplace.

8

Page 603: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

...... .. -._ • " '_ ...... ,.B[OCKWBE:L.;TA.i_PEAXLE. ' ..::- '" " ....... PREPaREFOR REASSEMBLY

CLEAN

Parts having ground and polished surfaces such as gears, bearings, ..shaftsand collars, should be cleaned.in a suitable solvent such as

:. ,- .- :- .ker.oser_e:_or.diesel_fuel.oil...._ . : .. .... .. ' ''.i"

• GASOLINE SHOULD BE AVOIDED.

• Do NOT clean these parts in a hot solution tank or with water and•. alkaline solutions such as sodium hydroxide, orthosilicates or

ii phosphates.I

:' -. -.. We dd _.NOT recommend steam cleaning assembled drive units after they.-._.:- .._/_ have been removed from the housing. When this method of cleaning is

_,:_- :':: used, water is trapped inthe cored passage of the castings and in the,, close clearance between parts as well as on the parts. This can lead to

'('. corrosion (rust) of critical parts of the assembly and the possibility.... of circulating rust particles in the lubricant. Premature failure of_ bearings, gears and other parts can be caused by this practice.

Assembled drive units cannot be properly cleaned by steam cleaning,dipping or slushing. Complete drive unit disassembly is a necessary

: _ requisite to thorough cleaning•

ROUGH PARTS

:: Rough:.parts-such as differential carrier castings, cast bracketsand some brake parts may be cleaned in hot solution tanks with mildalkali solutions providing these parts are not ground or polished. The-parts should.remain in the tank long enough to be thoroughly cleaned and

............... heated.through. _This will.aid.the evaporat on of the rinse wa.ter. The .................parts should be thoroughly rinsed after cleaning to remove all traces of alkali.

CAUTION: Exercise care to avoid skin rashes and,inhalation of vapors

when using alkali cleaners.

COMPLETE ASSEMBLIES

©ompletely assembled axles may be st.eam cleaned on the outside.only, to facilitate initial removal and disassembly, providing.all,openings are used. Breathers, vented shift units, and all otheropenings should be tightly covered or closed to prevent the possibility

of water entering the assembly.

DRYING

Parts should be thoroughly dried immediately after cleaning. Use .- - .soft, clean, lintless absorbent paper towels or wiping rags free of

abrasive material, such as lapping compound, metal filings orcontaminated oil. Bearings should never be dried by spinning with

compressed air.9

Page 604: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

ROCKWEELTATYPEAXLE"• : ,, , i}_

CORROSION PREVENTION

Parts that have been cleaned, dried, inspected and are to be•.... immediately reassembled should be coated with light oil to prevent

•_, . ._._..:_;:. .."oo:_r.osiQl_._.lf:.these;:parts;ar,e:_tezbe_stored:.fon any length_ of' time:¢hey... _..should be treated with a good RUST PREVENTIVE COATING and wrapped in aspecial paper or other material designed to prevent corrosion.

INSPECT

It is impossible to overstress the importance of carefull andthorough inspection of drive unit parts prior to reassembly. Thorough•visual inspection for indications of wear or stress, and the replacementof such parts as are necessary will eliminate costly, and avoidable ..driveunit failure.

A. Inspect all bearings cups and cones, including those not removedfrom parts of the drive unit and replace if rollers or.cups arepitted or damaged in any way. Remove parts needingreplacementwith a suitable puller or in a press with sleeves.

Avoid the use of drifts and hammers. They may.easily mutilate ordistort component parts.

B. Inspect first reduction bevel or hypoid and second •reduction spurgears for wear or damage. Gears which are pitted, galled or wornor broken through case hardening should be replaced.

When necessary to replace the pinion or gear of a spiral bevel orhypoid gear set, the entire gear set should be replaced. We assumeno responsibility for gears of these types when replaced in any-other manner.

C. Inspect the differential assembly for the following:

1. Pitted, scored or worn thrust surfaces of differential casehalves, thrust washers, spider trunnions and differentialgears.

Thrust washers must be replaced in sets. The use of acombination of old and new washers will result in prematurefailure.

2. Wear or damage to the differential pinion and side gear teeth.Always replace differential pinions and side gears in-sets.

©. Spur pinions for wear or damage to teeth.

10

Page 605: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

, ., ":, - " ' " :I":I::¢:ROGK.-WE:EI::::::_TA.TYPEAXLE• ; : ' .-. " ' .: . ., " • • " '..

E. Check end of pinion or indications of brinelling caused by wornsplines. Replace the parts if the splines of the pinion and orthru shaft are worn, permitting movement of the pinion on the thru-shaft.

'- r ;'.:: . " " . .

....- F. Axle shafts for indications of torsionaL fractures and runoutAxle shafts should be inspected between centers to ascertain theamount of runout of the ground surface. Runout at the shaftflange and splines should not exceed .005" total indicator reading.•

. REPAIR

-;.

,• A. Replace all worn or damaged parts. Hex nuts with rounded corners,,,:,:::..._. all lock-washers, oil seals and gaskets should be replaced at,the•..... _. time of overhaul•

Use only genuine Rockwell-Standard parts for satisfactory service.:.. : For example, using gaskets of foreign material generally leads to

mechanical trouble due to variations in thickness and the inabilityof certain materials to withstand compression, oil, etc.

B. Remove nicks, mars and burrs from machined or ground surfaces.Threads must be clean and free to obtain accurate adjustment and

:--' correct torque. A fine mill or India stone is suitable for thispurpose. Studs must be tight prior to reassembling the parts.

REASSEMBLE AXLE

Spiral Bevel

A. Press rear thrust and radial bearings firmly against the pinionshaft shoulder•

B. Install radial bearing lock ring and squeeze ring into pinion shaftgroove with pliers. -

C. If new cups are to be installed, press firmly against pinion cageshoulders.

D. Lubricate bearings and cups with light machine oil11

Page 606: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

.,', ,.

' . " -.,':R(DQKWELL-TA TYPE AXLE ._ • -

ASSEMBLE DIFFERENTIAL AND BEVEL GEAR

A. Bolt bevel gear to case half with new bolts. Nuts away from thegear. Torque to 70 ft. Ibs. If a new gear or differential case is

•_ : ,,._,.::--.:'._to::b:e,use:d:,in.theasser:_bly;_the,,bolt, holes in the gear .and case_::.should be checked, for alignment and line reamed, if necessary. Thegear must be tight on the case pilot.

•--.,"Yb- " " ':"

t .,,,_..j

B. Lubricate differential case inner walls and all component partswith axlelubricant.

C. Position thrust washer and side gear in bevel gear and case halfassembly.

D. Place spider with pinions and thrust washers in position.

E. Install component side gear and thrust washer.

F. Align mating marks, position component case half and draw assemblytogether with four bolts or cap screws equally spaced.

G. Check assembly for free rotation of differential gears and correctif necessary.

H. Install remaining bolts or cap screws, tighten to 100 ft. Ibs.

I. If bearings are to be replaced, press squarely and firmly ondifferential case halves.

12

Page 607: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" - ., , ROOKWEEL.,,T:A_,,TYPE.AXLE "... • _ . ..,. , .. . ,

REDUCTION GEAR BOX-REAR AXLE

- " ',, _ ,t

13

Page 608: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

" ' ':" ' - " ' .. ..'ROCKWEIZL..TA.TYPEAXLE ..." " " ,• .-[. -,' . ." • . • .

TO INSTALL INPUT PINION WITH BEARINGS AND CHECK PRELOAD

._-..1. Insert the pinion input shaft assembly (items 5, 48, 49, 50, 51,.... i_.5.T.,.." ' ....._, :,-:..,.::_ 2,:,:53 ,iL54f,,'.5:5'&,56). into_,the,;jcaErie.r.,housing.(item 1.6) .with a.new.'. ...

gasket, (item 47) over the studs.

2 Install the reduction box case half (item 58), to the carrier.Secure with look washers andnuts ( items 59 & 60). Torque nuts to150 ft. Ibs.

3. Install the large reduction gear (item 61) on the pinion shaft andtap on to seat.

"4. Installnut (item 63) and torque to 450 - 550 ft. Ibs. Use a blockof hardwood between the pinion gear teeth housing to lock thepinion shaft so that it can be torqued. After torquing, removewood block and wood splinters from the housing .and pinion teeth.

5. Check pinion bearings preload by rotating the pinion and gear withan inch pound torque wrench. Should be 5-15 inch pounds required

to rotate the pinion and gear assembly.

Preload is adjusted by using different thicknesses of spacer, (item55). Grind the spacer down to increase preload, cut a shim and addto the spacer to decrease preload. Different spacers are availableas a kit when ordering a new ring and pinion gear set.

6. Adjust preload as required and torque according to step #4 above.

7. Install Iockwasher, (item 64).

8. Install Iocknut (item 63) and torque to 450-550 ft. Ibs. Bend overtabs to look both nuts.

14

Page 609: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• :' ' • ' ROOKWELE TA TYPE AXLE

.,.. :,_ ..,...... .., . ,.,.:..:. L.tREAR,.DFglX/EAXLE ASSEMBLY •

15

Page 610: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

RO(DKWELLTA TYPE AXLE '

1. nsert differential case with gear over the axle shaft end and intothe housing half. No shims are required.

2. Using a new gasket (item 25), assemble the other case half together

' ' ": - " .iand:secure;with:screws::(_item_.:l.9), lock washers,, nuts::(item.20._&• . ; ','_,.

21), torque to 50 ft. Ibs. Make sure the mounting pads are in thesame position and level with each other.

ASSEMBLE DROP BOX

1. Install new bearings (items 75 & 77), as required on the inputshaft with gear (item 76).

"2. Install input shaft and bearing assembly. 'If a new bearing (item.77) was installed, remove the snap ring from (item 77).

3. Assemble cover (item 58) with new gasket (item 79), screws (item88), .lock washers (item 89), nuts (item 90). Torque bolts to 50ft. Ibs.

4. Install the snap ring (item 78), on to the end of the input gearand shaft with bearings (item 76) if the snap ring was removed toreplacethe bearing item 77).

5. Install the snap ring into the bearing (item 77).

6. Using a new gasket (item 84), install the rear bearing retainer(item 85), with the four screws and lock washers (items 87 & 72).Torque to 50 ft. Ibs.

7. Install the input flange (item 67), lock washer (item 66) and nut(item 65A). Torque to 200 ft. Ibs.

8. Refill with GL-5 axle lube 80W/140, 80W/140 or 75W/140 to bottom of

carrier fill plug and drop box fill plug. Allow the oil 1/2 hourto flow thru the bearings into the drop box and recheck oil level.1 0 quarts required.

16

Page 611: Manual t.o.w.  ford 300 tc (tig) tractor 2004.01

• ROCKWELL TA TYPE AXLE.

TOROUE SPECIFICATIONS

. .. .AREA'. TORQUE (FT. LBS..)

Axle Shaft to Hub Nut 400 TIGHTENTO ASSEMBLECOTTER KEY

Differential Case Screws 100

• !!DifferentialInput Pinion Nuts 450 - 5502'-

._. ,!:...... Drop Box Case Halves Screws • 50"4:-1

:,: Drop Box Case to Carrier Nuts. 150 - 190

:;_:lnputFlange Bearing Retainer Screws 502"

' InputFlangeNut 200

Lugnuts 100

Ring Gear to Differential Case 70

Wheel Bearing Retainer Screws 50

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