New Holland Rustler 120 125 Service Repair Workshop Manual

New Holland Rustler 120 125 Service Repair Workshop Manual

It is complete Workshop Repair Service Manual for New Holland Rustler series models:
Rustler 125 Gasoline
Rustler 120 Diesel

Language:English
Number of pages: 428

Contetns
SECTION 1 SAFETY
Safety Details ……………………………………………………………………………………………………………….. 1-1
General Warning ………………………………………………………………………………………………………………. 1-2
Disabling The Vehicle ……………………………………………………………………………………………………. 1-4
Disconnecting The Battery ……………………………………………………………………………………………… 1-4
Connecting The Battery …………………………………………………………………………………………………. 1-4
SECTION 2 VEHICLE SPECIFICATIONS
SECTION 3 GENERAL INFORMATION
General Information ………………………………………………………………………………………………………….. 3-1
Model Identification …………………………………………………………………………………………………………… 3-2
Identification Numbers …………………………………………………………………………………………………… 3-2
Storage …………………………………………………………………………………………………………………………… 3-4
Preparing the Vehicle for Extended Storage …………………………………………………………………….. 3-4
Returning the Stored Vehicle to Service …………………………………………………………………………… 3-5
Using A Booster Battery (Jump Starting) ……………………………………………………………………………… 3-6
SECTION 4 BODY AND TRIM
Cleaning the Vehicle …………………………………………………………………………………………………………. 4-1
Seat Cleaning ………………………………………………………………………………………………………………. 4-1
Front Body Repair …………………………………………………………………………………………………………….. 4-2
Light Scratches …………………………………………………………………………………………………………….. 4-2
Abrasions and Haze ……………………………………………………………………………………………………… 4-2
Large Scratches and Abrasions ………………………………………………………………………………………. 4-2
Front Body Components …………………………………………………………………………………………………… 4-3
Instrument Panel Removal …………………………………………………………………………………………….. 4-3
Instrument Panel Installation ………………………………………………………………………………………….. 4-3
Front Fascia Removal …………………………………………………………………………………………………… 4-4
Front Fascia Installation ………………………………………………………………………………………………… 4-4
Hood Removal ……………………………………………………………………………………………………………… 4-4
Hood Installation ………………………………………………………………………………………………………….. 4-4
Center Cowl Panel Removal ………………………………………………………………………………………….. 4-4
Center Cowl Panel Installation ……………………………………………………………………………………….. 4-5
Side Cowl Panel (Fender) Removal ………………………………………………………………………………… 4-5
Side Cowl Panel (Fender) Installation ……………………………………………………………………………… 4-5
Front Fender Flare Removal ………………………………………………………………………………………….. 4-6
Front Fender Flare Installation ……………………………………………………………………………………….. 4-6
Roll-Over Protective Structure (ROPS) ……………………………………………………………………………….. 4-6
ROPS Removal ……………………………………………………………………………………………………………. 4-6
ROPS Installation …………………………………………………………………………………………………………. 4-8
Seat ……………………………………………………………………………………………………………………………….. 4-9
Seat Removal ………………………………………………………………………………………………………………. 4-9
Seat Adjustment …………………………………………………………………………………………………………… 4-9
Seat Installation ……………………………………………………………………………………………………………. 4-9
Seat Support Removal ………………………………………………………………………………………………….. 4-10
Seat Support Installation ……………………………………………………………………………………………….. 4-10
Safety Belts …………………………………………………………………………………………………………………….. 4-10
Safety Belt Removal ……………………………………………………………………………………………………… 4-10
Safety Belt Installation …………………………………………………………………………………………………… 4-11
Cargo Bed Electric Lift …………………………………………………………………………………………………… 4-11
Testing the Bed Lift Motor ……………………………………………………………………………………………… 4-11
Bed Lift Motor Removal …………………………………………………………………………………………………. 4-11
Bed Lift Motor Installation ………………………………………………………………………………………………. 4-12
Cargo Bed Removal ……………………………………………………………………………………………………… 4-12
Cargo Bed Installation …………………………………………………………………………………………………… 4-12
Cargo Bed Manual Lift …………………………………………………………………………………………………… 4-13
Cargo Bed Removal ……………………………………………………………………………………………………… 4-13
Cargo Bed Installation …………………………………………………………………………………………………… 4-13
Rear Fender ……………………………………………………………………………………………………………………. 4-15
Rear Fender Removal …………………………………………………………………………………………………… 4-15
Rear Fender Installation ………………………………………………………………………………………………… 4-15
SECTION 5 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal …………………………………………………………………………………………………………….. 5-1
Accelerator Pedal Removal ……………………………………………………………………………………………. 5-1
Accelerator Pedal Installation …………………………………………………………………………………………. 5-2
Accelerator Pedal and RPM Adjustment ………………………………………………………………………….. 5-2
Brake Pedal …………………………………………………………………………………………………………………….. 5-3
Brake Pedal Removal ……………………………………………………………………………………………………. 5-3
Brake Pedal Installation …………………………………………………………………………………………………. 5-3
Brake Pedal Adjustment ………………………………………………………………………………………………… 5-3
Park Brake Pedal ……………………………………………………………………………………………………………… 5-4
Park Brake Pedal Assembly Removal ……………………………………………………………………………… 5-4
Park Brake Pedal Assembly Installation …………………………………………………………………………… 5-4
SECTION 6 HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection …………………………………………………………………………………………………… 6-1
Brake System Troubleshooting …………………………………………………………………………………………… 6-3
Brake Pads and Caliper …………………………………………………………………………………………………….. 6-5
Front Brake Pad and Caliper Removal …………………………………………………………………………….. 6-5
Front Brake Pad and Caliper Installation ………………………………………………………………………….. 6-7
Rear Brake Pad and Caliper Removal ……………………………………………………………………………… 6-8
Rear Brake Pad and Caliper Installation …………………………………………………………………………… 6-9
Brake Disc and Hub ………………………………………………………………………………………………………….. 6-10
Front Wheel Disc and Hub Removal ……………………………………………………………………………….. 6-10
Front Wheel Disc and Hub Installation …………………………………………………………………………….. 6-14
Rear Wheel Disc Removal ……………………………………………………………………………………………… 6-15
Rear Wheel Disc Installation …………………………………………………………………………………………… 6-16
Hydraulic Line Replacement ………………………………………………………………………………………………. 6-17
Front Brake Line Removal ……………………………………………………………………………………………… 6-17
Front Brake Line Installation …………………………………………………………………………………………… 6-17
Rear Brake Line Removal ………………………………………………………………………………………………. 6-18
Rear Brake Line Installation ……………………………………………………………………………………………. 6-19
Master Cylinder and Reservoir …………………………………………………………………………………………… 6-20
Filling the Hydraulic System …………………………………………………………………………………………… 6-20
Master Cylinder Removal ………………………………………………………………………………………………. 6-20
Master Cylinder Installation ……………………………………………………………………………………………. 6-21
Bleeding the Hydraulic Brake System …………………………………………………………………………………. 6-21
Bleeding Brakes on a DOT 5 Fluid Filled System ………………………………………………………………. 6-21
Purging the Hydraulic System ………………………………………………………………………………………… 6-23
Park Brake System ………………………………………………………………………………………………………….. 6-24
Park Brake Adjustment At Rear Calipers ………………………………………………………………………. 6-24
Park Brake Cable Adjustment ………………………………………………………………………………………… 6-24
Park Brake Wheel Cables ……………………………………………………………………………………………… 6-25
Front Park Brake Cable Removal ……………………………………………………………………………………. 6-26
Front Park Brake Cable Installation …………………………………………………………………………………. 6-27
Park Brake Equalizer Removal ………………………………………………………………………………………. 6-27
Park Brake Equalizer Installation ……………………………………………………………………………………. 6-28
SECTION 7 STEERING AND FRONT SUSPENSION
Steering Wheel ………………………………………………………………………………………………………………… 7-1
Steering Wheel Removal ……………………………………………………………………………………………….. 7-1
Steering Wheel Installation …………………………………………………………………………………………….. 7-2
Steering Column ……………………………………………………………………………………………………………… 7-2
Steering Column Removal …………………………………………………………………………………………….. 7-2
Steering Column Installation ………………………………………………………………………………………….. 7-3
Rack and Pinion ………………………………………………………………………………………………………………. 7-3
Rack and Pinion Removal ……………………………………………………………………………………………… 7-3
Rack and Pinion Installation …………………………………………………………………………………………… 7-4
Rack and Pinion Disassembly ………………………………………………………………………………………… 7-5
Rack and Pinion Assembly …………………………………………………………………………………………….. 7-9
Front Suspension …………………………………………………………………………………………………………….. 7-11
Wheel Alignment ………………………………………………………………………………………………………….. 7-11
Front Suspension Components ………………………………………………………………………………………….. 7-13
Steering Upright Removal ……………………………………………………………………………………………… 7-13
Upper A-Arm Removal ………………………………………………………………………………………………….. 7-14
Upper A-Arm Installation ……………………………………………………………………………………………….. 7-16
Lower A-Arm Removal ………………………………………………………………………………………………….. 7-16
Lower A-Arm Installation ……………………………………………………………………………………………….. 7-17
Front Coil-Over Shock Absorber Removal ……………………………………………………………………….. 7-18
Front Coil-Over Shock Absorber Installation …………………………………………………………………….. 7-19
Steering Upright Installation …………………………………………………………………………………………… 7-19
SECTION 8 WHEELS AND TIRES
General Information …………………………………………………………………………………………………………. 8-1
Wheels …………………………………………………………………………………………………………………………… 8-2
Wheel Removal ……………………………………………………………………………………………………………. 8-2
Wheel Installation …………………………………………………………………………………………………………. 8-2
Tires ……………………………………………………………………………………………………………………………….. 8-2
Tire Removal ……………………………………………………………………………………………………………….. 8-2
Tire Installation …………………………………………………………………………………………………………….. 8-3
SECTION 9 REAR SUSPENSION
Rear Coil-Over Shock Absorber …………………………………………………………………………………………. 9-1
Swing Arms ……………………………………………………………………………………………………………………… 9-2
Swing Arm Removal ……………………………………………………………………………………………………… 9-2
Swing Arm Installation …………………………………………………………………………………………………… 9-3
SECTION 10 PERIODIC MAINTENANCE
Periodic Service Schedule …………………………………………………………………………………………………. 10-1
Periodic Lubrication Schedule ……………………………………………………………………………………………. 10-4
Brake Fluid Reservoir ……………………………………………………………………………………………………….. 10-6
Brake Fluid …………………………………………………………………………………………………………………… 10-6
Engine Oil ……………………………………………………………………………………………………………………….. 10-6
Oil Pressure Gasoline Engine ………………………………………………………………………………………. 10-7
Engine Oil Level Check …………………………………………………………………………………………………. 10-7
Engine Oil and Filter Change ………………………………………………………………………………………….. 10-7
Oil Viscosity …………………………………………………………………………………………………………………. 10-11
Spark Plugs …………………………………………………………………………………………………………………….. 10-11
Spark Plug Cleaning And Inspection ……………………………………………………………………………….. 10-11
Spark Plug Gap Inspection …………………………………………………………………………………………….. 10-11
Gearcase Lubrication ………………………………………………………………………………………………………… 10-12
Lubrication Level Check for Front Differential, Transmission, and Rear Differential ……………….. 10-12
Lubrication Change for Front Differential, Transmission, and Rear Differential ……………………… 10-12
Engine Coolant Diesel Vehicles ……………………………………………………………………………………….. 10-13
Engine Coolant Level Check ………………………………………………………………………………………….. 10-13
Fueling Instructions …………………………………………………………………………………………………………… 10-14
Draining Water from Fuel Filter ……………………………………………………………………………………….. 10-15
Battery ……………………………………………………………………………………………………………………………. 10-16
SECTION 11A TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
Troubleshooting Guide ……………………………………………………………………………………………………… 11a-1
Wiring Diagram ………………………………………………………………………………………………………………… 11a-6
Test Procedures ………………………………………………………………………………………………………………. 11a-8
Index of Test Procedures ……………………………………………………………………………………………….. 11a-8
SECTION 11B TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES
Troubleshooting Guide ……………………………………………………………………………………………………… 11b-1
Wiring Diagram ……………………………………………………………………………………………………………….. 11b-6
Test Procedures ………………………………………………………………………………………………………………. 11b-8
Index of Test Procedures ………………………………………………………………………………………………. 11b-8
SECTION 12A ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter and Starter Solenoid ………………………………………………………………………………………………. 12a-1
Relays ……………………………………………………………………………………………………………………………. 12a-1
Neutral Switch …………………………………………………………………………………………………………………. 12a-2
Carburetor Solenoid …………………………………………………………………………………………………………. 12a-2
Carburetor Heater ……………………………………………………………………………………………………………. 12a-3
Voltage Regulator ……………………………………………………………………………………………………………. 12a-4
Warning Lights ………………………………………………………………………………………………………………… 12a-5
Fuel Gauge/Hour Meter ……………………………………………………………………………………………………. 12a-6
Key Switch ……………………………………………………………………………………………………………………… 12a-7
12-Volt Accessory Receptacle …………………………………………………………………………………………… 12a-8
Bed Lift Switch ………………………………………………………………………………………………………………… 12a-9
Bed Lift Circuit Breaker …………………………………………………………………………………………………….. 12a-9
Light Switch …………………………………………………………………………………………………………………….. 12a-10
Fuse ………………………………………………………………………………………………………………………………. 12a-10
Reverse Warning Buzzer (If Equipped) ……………………………………………………………………………….. 12a-11
Reverse Warning Buzzer Limit Switch (If Equipped) …………………………………………………………….. 12a-12
Front Differential Limit Switch ……………………………………………………………………………………………. 12a-13
Fuel Level Sending Unit ……………………………………………………………………………………………………. 12a-14
Ignition Coil and Charge Coil …………………………………………………………………………………………….. 12a-14
Oil Pressure Sensor …………………………………………………………………………………………………………. 12a-15
Headlights ………………………………………………………………………………………………………………………. 12a-15
Wire Harness Diodes ……………………………………………………………………………………………………….. 12a-16
Battery ……………………………………………………………………………………………………………………………. 12a-16
General Information ………………………………………………………………………………………………………. 12a-17
SECTION 12B ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid ………………………………………………………………………………………………. 12b-1
Relays ……………………………………………………………………………………………………………………………. 12b-1
Neutral Switch …………………………………………………………………………………………………………………. 12b-2
Fuel Solenoid ………………………………………………………………………………………………………………….. 12b-2
60-Amp Fusible Link ………………………………………………………………………………………………………… 12b-3
Warning Lights …………………………………………………………………………………………………………………. 12b-4
Fuel Gauge/Hour Meter …………………………………………………………………………………………………….. 12b-6
Key Switch ………………………………………………………………………………………………………………………. 12b-6
12-Volt Accessory Receptacle ……………………………………………………………………………………………. 12b-7
Bed Lift Switch …………………………………………………………………………………………………………………. 12b-8
Bed Lift Circuit Breaker ……………………………………………………………………………………………………… 12b-8
Light Switch …………………………………………………………………………………………………………………….. 12b-8
Fuse ……………………………………………………………………………………………………………………………….. 12b-9
Reverse Warning Buzzer (If Equipped) ……………………………………………………………………………….. 12b-10
Reverse Warning Buzzer Limit Switch (If Equipped) ……………………………………………………………… 12b-11
Front Differential Limit Switch …………………………………………………………………………………………….. 12b-12
Fuel Level Sending Unit …………………………………………………………………………………………………….. 12b-13
Alternator ………………………………………………………………………………………………………………………… 12b-13
Oil Pressure Sensor ………………………………………………………………………………………………………….. 12b-15
Headlights ……………………………………………………………………………………………………………………….. 12b-15
Thermostat Switch ……………………………………………………………………………………………………………. 12b-16
Fan …………………………………………………………………………………………………………………………………. 12b-18
Wire Harness Diodes ………………………………………………………………………………………………………… 12b-19
Battery ……………………………………………………………………………………………………………………………. 12b-20
General Information ………………………………………………………………………………………………………. 12b-20
SECTION 13A GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Gasoline Engine ………………………………………………………………………………………………………………. 13a-1
Engine Removal …………………………………………………………………………………………………………… 13a-1
Engine Installation ………………………………………………………………………………………………………… 13a-3
Oil Filter Hoses …………………………………………………………………………………………………………….. 13a-5
Exhaust System ……………………………………………………………………………………………………………….. 13a-6
Muffler Removal ……………………………………………………………………………………………………………. 13a-6
Intermediate Pipe Removal ……………………………………………………………………………………………. 13a-7
Intermediate Pipe Installation …………………………………………………………………………………………. 13a-7
Muffler Installation …………………………………………………………………………………………………………. 13a-8
Fuel System ……………………………………………………………………………………………………………………. 13a-9
Fuel Lines ……………………………………………………………………………………………………………………. 13a-9
Fuel Filter …………………………………………………………………………………………………………………….. 13a-11
Fuel Pump …………………………………………………………………………………………………………………… 13a-11
Carburetor ……………………………………………………………………………………………………………………. 13a-11
Fuel Level Sending Unit …………………………………………………………………………………………………. 13a-12
Fuel Tank …………………………………………………………………………………………………………………….. 13a-16
Carbon Canister ……………………………………………………………………………………………………………. 13a-18
Fuel Shut-Off Valve ………………………………………………………………………………………………………. 13a-20
Engine Control Linkages …………………………………………………………………………………………………… 13a-21
Accelerator Cable …………………………………………………………………………………………………………. 13a-21
Choke Cable ……………………………………………………………………………………………………………….. 13a-23
Engine Governor Arm ……………………………………………………………………………………………………. 13a-25
Engine RPM Adjustment ……………………………………………………………………………………………….. 13a-25
Air Intake System …………………………………………………………………………………………………………….. 13a-26
Air Filter Replacement …………………………………………………………………………………………………… 13a-26
Air Canister Removal ……………………………………………………………………………………………………. 13a-27
Air Canister Installation …………………………………………………………………………………………………. 13a-27
Air Filter Intake Hose Removal ……………………………………………………………………………………….. 13a-28
Air Filter Intake Hose Installation …………………………………………………………………………………….. 13a-28
Air Filter Outlet Hose Removal ……………………………………………………………………………………….. 13a-29
Air Filter Outlet Hose Installation …………………………………………………………………………………….. 13a-29
Clutches …………………………………………………………………………………………………………………………. 13a-30
Clutch Troubleshooting …………………………………………………………………………………………………. 13a-30
Drive Belt …………………………………………………………………………………………………………………….. 13a-31
Drive Clutch …………………………………………………………………………………………………………………. 13a-32
Driven Clutch ……………………………………………………………………………………………………………….. 13a-37
Clutch Cover ………………………………………………………………………………………………………………… 13a-40
SECTION 13B DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine ………………………………………………………………………………………………………………….. 13b-1
Engine Removal …………………………………………………………………………………………………………… 13b-1
Engine Installation ………………………………………………………………………………………………………… 13b-3
Exhaust System ………………………………………………………………………………………………………………. 13b-5
Muffler Removal …………………………………………………………………………………………………………… 13b-5
Intermediate Pipe Removal ……………………………………………………………………………………………. 13b-5
Manifold Pipe Removal …………………………………………………………………………………………………. 13b-6
Manifold Pipe Installation ………………………………………………………………………………………………. 13b-6
Intermediate Pipe Installation …………………………………………………………………………………………. 13b-6
Muffler Installation ………………………………………………………………………………………………………… 13b-7
Fuel System …………………………………………………………………………………………………………………… 13b-8
Fuel Lines ……………………………………………………………………………………………………………………. 13b-8
Bleeding Air From Fuel System ………………………………………………………………………………………. 13b-9
Fuel Filter Replacement ………………………………………………………………………………………………… 13b-9
Fuel Pump …………………………………………………………………………………………………………………… 13b-11
Fuel Level Sending Unit ………………………………………………………………………………………………… 13b-11
Fuel Tank ……………………………………………………………………………………………………………………. 13b-15
Engine Control Linkages …………………………………………………………………………………………………… 13b-18
Accelerator Cable …………………………………………………………………………………………………………. 13b-18
Engine RPM Adjustment ……………………………………………………………………………………………….. 13b-20
Air Intake System ……………………………………………………………………………………………………………… 13b-22
Air Filter Replacement …………………………………………………………………………………………………… 13b-22
Air Canister Removal …………………………………………………………………………………………………….. 13b-23
Air Canister Installation ………………………………………………………………………………………………….. 13b-24
Air Filter Intake Hose Removal ……………………………………………………………………………………….. 13b-24
Air Filter Intake Hose Installation …………………………………………………………………………………….. 13b-25
Air Filter Outlet Hose Removal ……………………………………………………………………………………….. 13b-25
Air Filter Outlet Hose Installation …………………………………………………………………………………….. 13b-25
Clutches ………………………………………………………………………………………………………………………….. 13b-26
Clutch Troubleshooting ………………………………………………………………………………………………….. 13b-26
Drive Belt …………………………………………………………………………………………………………………….. 13b-27
Drive Clutch …………………………………………………………………………………………………………………. 13b-28
Driven Clutch ……………………………………………………………………………………………………………….. 13b-32
Clutch Cover ………………………………………………………………………………………………………………… 13b-34
SECTION 14 DRIVETRAIN COMPONENTS
Half Shafts ………………………………………………………………………………………………………………………. 14-1
Half Shaft Removal ……………………………………………………………………………………………………….. 14-1
Half Shaft Installation …………………………………………………………………………………………………….. 14-3
Front Differential ………………………………………………………………………………………………………………. 14-4
Front Differential Removal ……………………………………………………………………………………………… 14-4
Front Differential Installation …………………………………………………………………………………………… 14-6
Front Driveshaft ……………………………………………………………………………………………………………….. 14-6
Front Driveshaft Removal ………………………………………………………………………………………………. 14-6
Front Driveshaft Installation ……………………………………………………………………………………………. 14-7
Rear Receiver Hitch ………………………………………………………………………………………………………….. 14-7
Rear Receiver Hitch Removal ………………………………………………………………………………………… 14-7
Rear Receiver Hitch Installation ……………………………………………………………………………………… 14-7
Rear Axle ………………………………………………………………………………………………………………………… 14-8
Rear Axle Removal ……………………………………………………………………………………………………….. 14-8
Rear Axle Installation …………………………………………………………………………………………………….. 14-10
Rear Driveshaft ………………………………………………………………………………………………………………… 14-11
Rear Driveshaft Removal ……………………………………………………………………………………………….. 14-11
Rear Driveshaft Installation …………………………………………………………………………………………….. 14-12
Transmission …………………………………………………………………………………………………………………… 14-12
Transmission Removal ………………………………………………………………………………………………….. 14-12
Transmission Installation ……………………………………………………………………………………………….. 14-14
Forward/Reverse Shifter Cable ………………………………………………………………………………………. 14-15
Forward/Reverse Shifter Handle …………………………………………………………………………………….. 14-18
Rear Differential and Axle Shafts ……………………………………………………………………………………….. 14-18
Rear Differential and Axle Shaft Removal ………………………………………………………………………… 14-18
Rear Differential and Axle Shaft Installation ……………………………………………………………………… 14-20
Rear Wheel Bearings ……………………………………………………………………………………………………. 14-20
SECTION 15 RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information …………………………………………………………………………………………………………. 15-1
Engine Coolant Level Check ………………………………………………………………………………………….. 15-1
Engine Coolant Change ………………………………………………………………………………………………… 15-1
Coolant Reservoir ……………………………………………………………………………………………………………. 15-3
Coolant Reservoir Removal …………………………………………………………………………………………… 15-3
Coolant Reservoir Installation ………………………………………………………………………………………… 15-4
Radiator ………………………………………………………………………………………………………………………….. 15-4
Radiator Removal …………………………………………………………………………………………………………. 15-4
Radiator Installation ………………………………………………………………………………………………………. 15-5
Coolant Pipe Weldment ……………………………………………………………………………………………………. 15-6
Coolant Pipe Weldment Removal …………………………………………………………………………………… 15-6
Coolant Pipe Weldment Installation ………………………………………………………………………………… 15-6
Fan ………………………………………………………………………………………………………………………………… 15-7
Fan Removal ……………………………………………………………………………………………………………….. 15-7
Fan Installation …………………………………………………………………………………………………………….. 15-7
SECTION 16 TRANSMISSION
General Information …………………………………………………………………………………………………………. 16-1
Service Fixture ………………………………………………………………………………………………………………… 16-1
Transmission Removal ……………………………………………………………………………………………………… 16-2
Transmission Disassembly ……………………………………………………………………………………………….. 16-2
Input Shaft Disassembly ………………………………………………………………………………………………… 16-8
Input Shaft Assembly ……………………………………………………………………………………………………. 16-8
Intermediate Shaft Disassembly ……………………………………………………………………………………… 16-8
Output Shaft Disassembly ……………………………………………………………………………………………… 16-12
Shifter Shaft Removal …………………………………………………………………………………………………… 16-13
Shifter Shaft Installation ………………………………………………………………………………………………… 16-14
Case Inspection …………………………………………………………………………………………………………… 16-14
Shaft Seal Removal ………………………………………………………………………………………………………. 16-15
Shaft Seal Installation …………………………………………………………………………………………………… 16-15
Output Shaft Assembly ………………………………………………………………………………………………….. 16-15
Intermediate Shaft Assembly …………………………………………………………………………………………. 16-18
Intermediate and Output Shaft Assembly …………………………………………………………………………. 16-22
Transmission Assembly ……………………………………………………………………………………………………. 16-23
Transmission Installation …………………………………………………………………………………………………… 16-27
SECTION 17 FRONT DIFFERENTIAL
General Information ………………………………………………………………………………………………………….. 17-1
Axle Half Shaft Removal ……………………………………………………………………………………………………. 17-1
Front Differential Removal …………………………………………………………………………………………………. 17-2
Tools Required For This Section ……………………………………………………………………………………. 17-3
Front Differential Coil And Output Cover ……………………………………………………………………………… 17-3
Coil and Output Cover Removal ……………………………………………………………………………………… 17-3
Coil and Output Cover Installation …………………………………………………………………………………… 17-6
Front Differential ………………………………………………………………………………………………………………. 17-8
Front Differential Disassembly ………………………………………………………………………………………… 17-8
Front Differential Assembly …………………………………………………………………………………………….. 17-14
Front Differential Installation ………………………………………………………………………………………………. 17-18
Axle Half Shaft Installation …………………………………………………………………………………………………. 17-18
SECTION 18 REAR DIFFERENTIAL
General Information ………………………………………………………………………………………………………….. 18-1
Axle Shafts and Differential Removal ………………………………………………………………………………….. 18-2
Rear Differential Disassembly ……………………………………………………………………………………………. 18-2
Pinion Gear Removal …………………………………………………………………………………………………….. 18-4
Ring Gear Removal ………………………………………………………………………………………………………. 18-6
Clutch Carrier ……………………………………………………………………………………………………………….. 18-7
Clutch Components ………………………………………………………………………………………………………. 18-7
Ring Gear Installation ……………………………………………………………………………………………………. 18-9
Pinion Gear Installation ………………………………………………………………………………………………….. 18-9
Rear Differential Assembly …………………………………………………………………………………………….. 18-10
Axle Shafts and Differential Installation ……………………………………………………………………………….. 18-11

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