Ford 4100 Tractor Workshop Service Repair Manual

SHOP MANUAL FORD MODELS 2310-2600-2610-3600-3610-4100 (After 1974)-4110-4600- 4610 (Prior To 1984)-4e00SU-4610SU (Prior To 1984) Tractor Series (dentification Piate is iocated under right hood panei. Tractor Serial Number, aiong with manufacturing and production code numbers and tractor model number, will appear on implement mounting pad at right front corner of transmission (directly behind engine starter). Numbers will be stamped on top of pad, on mounting face of pad, or partially on top of and partially on mounting face of pad. Refer to foilowing explanation of the numbers that will appear at this location: Tractor Serial Number Tractor Manufacturing Code Number Transmission Production Code Number Traotor Modei Number Tractor Production Code Number Engine Seriai Number, aiong with tractor size identification, engine type identification and engine product code number, wiii appear on either the ieft or right pan raii of cyiinder biock casting approximateiy at mid-iength of engine. Refer to foilowing expianation of the numbers that wiii appear at this iooation: Tractor Identification Engine Type Engine Seriai Number Engine Production Code Number Tractor identification: B-2310-2600-2610 C-3600-3610 D-4100-4110-4600- 4610-4600SU-4610SU Engine Type: (Early) Late) D-Diesei 1& 5-Diesel G - Gasoiine 2 & 6 - Gasoiine P-LPGas The foliowing traotor modeis are covered in this manuai: 231 OAii Purpose 2600 Aii Purpose 2610 Aii Purpose 3600 Ali Purpose 3610 Aii Purpose 4100 Ali Purpose (After 1974) 4110 Ail Purpose 4600 Aii Purpose 4610 Aii Purpose (Prior To 1984) 4600SU 4610SU (Prior To 1984)

INDEX (By Starting Paragraph) BRAKES 207 CAB 137 CARBURETOR, GASOLINE 94 CLUTCH, SINGLE DISC 135 CLUTCH, DUAL DISC 136 CLUTCH, POWER TAKE OFF 231,243 COOLING SYSTEM: Radiator 122 Thermostat 121 Water Pump 123 DIESEL FUEL SYSTEM: Bleeding 104 Filters 103 Injection Pump 114 Injector Nozzles 105 Troubleshooting 95 DIFFERENTIAL 177,197 DIFFERENTIAL LOCK 183,201 ELECTRICAL SYSTEM: Alternator and Regulator 124 Ignition Distributor 129 Starting Motor 126 Wiring Diagram Page 99 ENGINE: Assembly, R&R 59 Camshaft 76 Connecting Rod Bearings 84 Crankshaft and Bearings 85 Crankshaft Oil Seals 86 Cylinder Head 61 Cylinders 80 Flywheel, R&R 89 Oil Pan 90 Oil Pump 91 Pistons and Rings 78 Piston and Rod Removal 77 Piston Pins 83 Rocker Arms 67 Timing Gear Cover 68 Timing Gears 71 ENGINE, CONT. Valve Adjustment 64 Valves and Seats 62 Valve Guides and Springs 63 Valve Rotators 65 FINAL DRIVE GEARS 179,206 FRONT AXLE 1, 20,35 GOVERNOR: Diesel 117 Non-Diesel 119 HYDRAULIC LIFT SYSTEM: Adjustments 258 De-Luxe Control Valves 297 Lift Cover Assembly, R&R ,, 263 Lift Cylinder, Overhaul 265 Priority Valve 277 Pump (Piston Type) 280 Pump (Engine Mounted Gear Type) 285 Pump (Internally Mounted Gear Type) 287 Pump (Engine Mounted Tandem Gear Type) 289 Remote Control Valves .293 Selector Valve 291 Troubleshooting 253 IGNITION SYSTEM .127 POWER STEERING: Bleed System 10,30 Control Valve 13 Pump 12 SteeringGear 13,27,33 System Pressure 11,31 POWER TAKE-OFF 220,225,236 REAR AXLE: Axle Housings 193,205 Bearing Adjustment 178, 206 Reduction Gear 171,172 Shaft, R&R 190, 206 STEERING (Manual) 5,24 TRANSMISSION: Six-Speed 139 Eight-Speed (Non-Synchromesh) 149 Eight-Speed (Synchromesh) 158 DUAL DIMENSIONS This service manuai provides specifications in both the U.S. Customary and Metric (SI) systems of measurement. The first specification is given in the measuring system per- ceived by us to be the preferred system when servicing a particuiar component, whiie the second specification (given in parenthesis) is the converted measurement. For instance, a specificaiton of "0.011 inch (0.28 mm)" would indicate that we feei the preferred measurement, in this instance, is the U.S. system of measurement and the metric equivalent of 0.011 inch is 0.28 mm.

CONDENSED SERVICE DATA GENERAL Engine Make No. of Cylinders Bore, Inches: Non-Diesel Diesel Bore, mm: Non-Diesel Diesel Stroke, Inches: Non-Diesel Diesel Stroke, mm: Non-Diesel Diesel Displacement, Cubic Inches: Non-Diesel Diesel . . . . . Displacement, cc: Non-Diesel .... Diesel Compression Ratio: Non-Diesel Diesel Firing Order Valve Tappet Gap (Warm): Intake Valve Face Angle, Degrees: Intake Exhaust Valve Seat Angle, Degrees: Intake Exhaust Ignition Timing SDark Pluer Make Soark Pluff Tvpe . Engine Low Idle rpm* Engine High Idle, rpm: Non-Diesel Diesel Engine Rated rpm: Non-Diesel Diesel .. Grounded Battery Terminal 2600 Own 3 4.2 4.2 106.7 106.7 3.8 3.8 96.5 96.5 158 158 2589 2589 8.0:1 17.3:1 1-2-3 44 44 45 45 Par. 128 Motorcraft AG-5 600-700 2200-2300 2225-2275 2000 2000 Negative 3600 Own 3 4.2 4.2 106.7 106.7 4.2 4.2 106.7 106.7 175 175 2867 2867 8.0:1 16.3:1 4100 Own 3 \'-'',: 4.2 106.7 4.4 111.8 183 2998 16.3:1 1-2-3 1-2-3 0 014-0 016 inch (0 355-0 406 mm) 0 017-0 019 inch ^^ A9.^ M A9,9. mm^ 44 44 45 45 Par. 128 Motorcraft AG-5 600-700 2200-2300 2225-2275 2000 2000 Negative 44 44 45 45 TTflTlh 11^ 600-700 2425-2475 2200 Negative 4600, 4600SU Own 3 4.4 4.4 111.8 111.8 4.4 4.4 111.8 111.8 201 201 3293 3293 8.0:1 16.3:1 1-2-3 44 44 45 45 Par. 128 Motorcraft AG-5 600-700 2400-2500 2425-2475 2200 2200 Negative SIZES-CAPACITIES-CLEARANCES Crankshaft Journal Diameter — Crankpin Diameter — Camshaft Journal Diameter — Piston Pin Diameter — Valve Stem Diameter, Intake — Valve Stem Diameter, Exhaust — — See Paragraph 85 - — See Paragraph 84 - -2.3895-2.3905inches- (60.693-60.718 mm) -1.4997-1.5000 inches- (38.092-38.100 mm) -0.3711-0.3718 inch - (9.425-9.443 mm) -0.3701-0.3708 inch - (9.400-9.418 mm)

CONDENSED SERVICE DATA (CONT.) 2600 3600 4100 4600,4600SU SIZES-CAPACITIES-CLEARANCES, CONT. Main Bearing Diametral Clearance — 0.0022-0.0045 inch (0.0559-0.1143 mm) Rod Bearing Diametral w Clearance: Aluminum 0.0021-0.0042 inch (0.053-0.107 mm) Copper-Lead 0.0017-0.0038 inch (0.0431-0.0965 mm) Camshaft Bearing Diametral Clearance 0.001-0.003 inch (0.0254-0.0762 mm) Crankshaft End Play 0.004-0.008 inch • (0.1016-0.2032 mm) Camshaft End Play 0.001-0.007 inch (0.0254-0.1778 mm) Piston Skirt-to-Cylinder Clearance See Paragraph 82 Cooling System (Less Heater): Quarts(U.S.) H — Liters 10.41 Crankcase With Filter: Quarts(U.S.) 7 Liters —- 6.65 — — Transmission!!!!!!!!!!!!!!!!!!!! See Paragraph 139,149 Final Drive & Hydraulic: Quarts(U.S.) 24.6 24.6 48.3 48.3 Liters 23.37 23.37 45.88 45.88 Steering Gear Manual: Quarts (U.S.) —0.66 Liters. 0.63 Power Steering: Quarts(U.S.) 1.9* 1.9* 1.9* 2.3** Liters ...... 1.8 1.8 1.8 2.2 *Oil capacity is 2.3 U.S. quarts (2.2 liters) on models equipped with a cab. **Oil capacity is 1.9 U.S. quarts (1.8 liters) on Model 4600SU when not equipped with a cab. 2310 2610 3610 4110 4610,4610SU GENERAL Engine Make Own Own Own Own Own No. of Cylinders 3 3 3 3 3 Bore, Inches: Non-Diesel... 4.2 4.2 ..... 4.4 Diesel 4.2 4.2 4.4 4.4 4.4 Bore, mm: Non-Diesel 106.7 106.7 111.8 Diesel 106.7 106.7 111.8 111.8 111.8 Stroke, Inches: Non-Diesel 3.8 4.2 4.4 Diesel 3.8 4.2 4.2 4.4 4.4 Stroke, mm: Non-Diesel ..... 96.5 106.7 .... 111.8 Diesel 96.5 106.7 106.7 111.8 111.8 Displacement, Cubic Inches: Non-Diesel 158 175 201 Diesel 158 175 192 201 201 Displacement, cc: Non-Diesel 2589 2867 3293 Diesel 2589 2867 3146 3293 3293 Compression Ratio: Non-Diesel 7.75:1 7.75:1 7.75:1 Diesel 17.3:1 17.3:1 16.3:1 16.3:1 See Par. 79 Firing Order 1-2-3 1-2-3 1-2-3 1-2-3 1-2-3 Valve Tappet Gap (Warm): Intake 0.014-0.016 inch (0.355-0.406 mm) Exhaust 0.017-0.019 inch (0.431-0.482 mm) —

CONDENSED SERVICE DATA (CONT.) GENERAL, CONT. 2310 2610 3610 Valve Face Angle, Degrees: Intake 44.5 44.5 44.5 Exhaust 44.5 44.5 44.5 Valve Seat Angle, Degrees: Intake 45 45 45 Exhaust 45 45 45 Ignition Timing Par. 128 Par. 128 Injection Timing See Paragraph 114 Spark Plug Make Motorcraft Motorcraft Spark PlugType AG-5 AG-5 Engine Low Idle, rpm: 600-850 600-850 600-850 Engine High Idle, rpm: Non-Diesel 2250-2350 2250-2350 Diesel 2225-2275 2225-2275 2225-2275 Engine Rated Speed, rpm: Non-Diesel 2000 2000 Diesel 2000 2000 2000 Grounded Battery Terminal Negative Negative Negative SIZES - CAPACITIES - CLEARANCES Crankshaft Journal Diameter See Paragraph 85 Crankpin Diameter See Paragraph 84 Camshaft Journal Diameter — 2.3895-2.3905 inches (60.693-60.718 mm) Piston Pin Diameter —_ 1.4997-1.5000 inches (38.092-38.100 mm) Valve Stem Diameter, Intake ~ 0.3711-0.3718 inch (9.425-9.443 mm) Valve Stem Diameter, Exhaust 0.3701-0.3708 inch , , . „ . (9.400-9.418 mm) Mam Bearmg Diametral ' Clearance — 0.0022-0.0045 inch (0.0559-0.1143 mm) Rod Bearing Diametral Clearance: Aluminum . 0.0021-0.0042 inch (0.053-0.107 mm) Copper-Lead 0.0017-0.0038 inch (0.0431-0.0965 mm) Camshaft Bearing Diametral Clearance 0.001-0.003 inch (0.0254-0.0762 mm) Crankshaft End Play _ 0.004-0.008 inch (0.1016-0.2032 mm) Camshaft End Play _ 0.001-0.007 inch (0.0254-0.1778 mm) Piston Skirt-to-Cylinder Clearance _ See Paragraph 82 Cooling System (Less Heater): Quarts (U.S.) H Liters - JQ 41 Crankcase With Filter: Quarts (U.S.) . 7 Liters-. _ 6.65 Transmission See Paragraph 149,158 Final Drive & Hydraulic: Quarts(U.S.) 24.6 24.6 24.6 48 3 Liters 23.37 23.37 23.37 45.88 Steering Gear, Manual: Quarts(U.S.) 0.66 Liters . 0.63 Power Steering: Quarts (U.S.) 1.9* 1.9* 1.9* 1.9* Liters 1.8 1.8 1.8 1.8 *Oil capacity is 2.3 U.S. quarts (2.2 liters) on models equipped with a cab. **Oil capacity is 1.9 U.S. quarts (1.8 liters) on Model 4610SU when not equipped with a cab. 4110 44.5 \ 44.5 45 45 600-850 2425-2475 2200 Negative 4610,4610SU 44.5 44.5 45 45 Par. 128 Motorcraft AG-5 600-850 2450-2550 2350-2400 2200 2200 Negative 48.3 45.88 2.3** 2.2 6

SHOP MANUAL Paragraphs 1-8 FRONT SYSTEM AND STEERING (Models 2310-2600-2610-3600-3610-4100-4110 Without Cab) FRONT AXLE ASSEMBLY AND STEERING LINKAGE 1. SPINDLE BUSHINGS. To renew spindle bushings (19 and 22-Fig. 1), proceed as follows: Support front of tractor and disconnect steering arms (17) from wheel spindles (24). Slide spindle out of axle extension (21). Drive old bushings from front axle extension and install new ones using a piloted drift or bushing driver. New bushings will not require final sizing if not distorted dur- ing installation. Renew thrust bearing (23) if worn or rough. 2. AXLE CENTER MEMBER, PIV- OT PIN AND BUSHINGS. To remove axle center member (6-Fig 1), support front of tractor, unbolt axle extensions from axle center member and swing axle extensions and wheel assemblies away from tractor. Remove cap screw (1) and retainer (2), then unscrew front axle pivot pin (3). Withdraw axle center member from either side of tractor. Press out bushing (7). To reassemble, press a new bushing into axle center member. Insert axle center member into front support, install pivot pin and tighten pin to 300-320 ft.-lbs. (408-435 N-m). Install retainer (2) and tighten cap screw (1) to 75 ft.-lbs. (102 N'm). If removed, tighten radius rod to axle extension bolts to 130-160 ft.-lbs. (176-217 N-m). 3. FRONT SUPPORT. To remove front support, proceed as follows: Remove engine hood, grille, lower hood to front support bolts and unbolt radiator from front support. Place floor jack under front end of transmission and take weight of tractor from front axle. Remove front axle pivot pin as in paragraph 2. Remove bolts retaining front support casting to engine and lower front support to floor. When reinstalling, tighten front support bolts to 180-220 ft.-lbs. (244-299 N-m). 4. DRAG LINKS AND TOE-IN. Drag link ends are non-adjustable automotive type and renewal procedure is evident. Refer to Fig. 1 for manual steering tractors and to Fig. 4 for power steering. Front wheel toe-in should be V4- to V2-inch (6.35 to 12.7 mm); vary the length of each drag link an equal amount to obtain proper toe-in. MANUAL STEERING GEAR 5. ADJUSTMENT. To adjust steering gear, first be sure gear housing is Fig. 1-Exploded view of front axte and related parts used on Models 2310, 2600, 2610, 3600, 3610, 4100 and 4110 without a cab. 1. Cap screw 2. Retainer 3. Pivot pin 4. Front support 5. Retainer 6. Axle center member 7. Bushing 8. Front drag link end 9. Clamp 10. Drag link 11. Steering gear assy. 12. Dust cover 13. Rear drag link end 14. Radius rod ball spacer 15. Radius rod cap 16. Radius rod 17. Steering arm 18. Dust seal 19. Spindle bushing, upper 20. Grease fitting 21. Axle extension, L.H. 22. Spindle bushing, lower 23. Thrust bearing 24. Spindle 25. Steering arm key properly filled, then disconnect both drag links from steering arms and proceed as follows: 6. WORMSHAFT END PLAY. To check wormshaft end play, first loosen locknuts (1-Fig. 2) on sector shaft adjusting screws (8) and back screws out two full turns. Wormshaft should turn freely without perceptible end play. Shims (24) are available in thicknesses of 0.0024 inch (0.060 mm) (brass), 0.005 inch (0.127 mm) (steel) and 0.010 inch (0.254 mm) (steel); also, a 0.005 inch (0.127 mm) thick paper gasket is available. Install at least one paper gasket and brass or steel shims as required. Tighten steering shaft cover retaining cap screws to a torque of 25 ft.-lbs. (34 N'm). Renew wormshaft bearings as outlined in paragraph 9 if end play is perceptible with paper gasket, but without any metal shims in- stalled. After checking or adjusting wormshaft end play, readjust sector shaft end play as follows: 7. SECTOR SHAFT END PLAY. Before adjusting sector shaft end play, be sure wormshaft is properly adjusted as outlined in paragraphs 5 and 6, then proceed as follows: Turn steering wheel to mid or straight-ahead position. With locknuts on both sector shaft adjusting screws loosened and adjusting screw on forward sector shaft (left side) backed out several turns, turn sector shaft adjusting screw (right side) in until there is no perceptible end play in rear sector shaft (13-Fig. 2). Tighten locknut while holding adjusting screw. Turn adjusting screw on left side of unit (front sector shaft) in until there is no perceptible end play of front sector shaft (9). Hold the adjusting screw and tighten locknut. Adjustment of steering gear is correct if a pull of 1 to 2% lbs. (0.45 to 1.23 kg) is required at outer edge of steering wheel to turn steering gear over center position. When adjustment of sector shafts is correct, reconnect drag links to steering arms. 8. R&R STEERING GEAR AS- SEMBLY. To remove steering gear assembly proceed as follows: Disconnect battery and remove engine hood panel. Disconnect wiring harness plug located forward of fuel tank and safety start switch. Detach proofmeter cable at front connection. Remove steering wheel and sheet metal covers at each side of steer-

Paragraphs 9-11 FORD ing gear. Disconnect throttle linkage and remove rear hood panel. Disconnect fuel gage sender wire and all other wires which will interfere with fuel tank removal. Shut off fuel supply, disconnect fuel supply line and diesel fuel return line from tank, then remove fuel tank assembly. Thoroughly clean steering gear and surrounding area. Discon- nect drag links from steering arms, then unbolt and remove steering gear assembly from transmission housing. Drain lubricant from steering gear housing if unit is to be disassembled. To reinstall steering gear, reverse removal procedure. Refill gear housing with Ford 134 oil. 9. OVERHAUL. Major overhaul of steering gear unit necessitates removal of the unit from the tractor as outlined in paragraph 8. After removing unit, refer to Fig. 2 and proceed as follows: Remove steering arm retaining nuts (14) and pull steering arms (10 and 16) from sector shafts (9 and 13). Sector shafts and side covers (4) can be removed as a unit after removing cover retaining screws. To separate shaft and cover, remove locknut (1) and thread adjusting screw (8) into cover until threads clear. Unbolt steering shaft cover (27) from gear housing (11) and remove cover, shaft and ball nut assembly. Do not disassemble ball nut and steering shaft assembly (23) as component replace- ment parts are not available. If steering shaft and/or ball nut are damaged, renew the complete assembly. The need and procedure for further disassembly and/or overhaul is evident from inspec- tion of the unit. Gear housing sector shaft bushings are not serviced separately from housing; install a new housing if bushings are excessively worn. Bushings (5) are renewable. Shims (7) on adjusting screws (8) are available in thicknesses of 0.063, 0.064, 0.066 and 0.069 inch (1.600,1.625,1.676 and 1.752 mm). When reassembling, select a shim that will provide 0.000-0.002 inch (0.00-0.05 mm) clearance between adjusting screw head and slot in sector shaft. To reassemble, insert steering shaft and ball nut unit into gear housing with gear teeth on ball nut forward, then install steering shaft housing (27) with proper number of shims as outlined in paragraph 6. Insert sector shafts, with their adjusting screws and correct thickness shims, into gear housing so sector gear teeth and ball nut teeth are timed as shown in Fig. 3. Place new "0" rings (6-Fig. 2) on side covers (4) and pull side covers into place with sector shaft adjustment screws. Install and tighten side cover retaining cap screws to a tor- Fig. 2-Exploded view of manual steering gear assembly used on Models 2310, 2600, 2610, 3600, 3610, 4100 and 4110 without a cab, Wormshaft (23) end play Is adjustable by varying thickness of shims (24^ sector shaft end play Is adjusted by screws (8), Select a shim (7) that will provide 0.0000.002 inch (0.000.05 mm) clearance between head of adjusting screw (8) and slot In sector shaft (9 or 1. Locknut - r 2. Washer 3. Packing 4. Side covers 5. Bushing 6. "O"ring 7. Shim 8. Adjusting screw 9. Sector gear (single) 10. Steering arm, L.H. 11. Housing 13. Sector gear (double) 14. Nut 15. Washer 16. Steering arm, R.H. 17. Felt dust seal 18. Oil sea] 19. Bearing cup 20. Bearing cone & rollers 21. Bearing retainer eyelet 22. Bearing retainer 23. Wormshaft assy. 24. Shims 25. Bearing cone & rollers 26. Bearing cup 27. Steering column 26. Bearing cup 27. Steering column 28. Bushing 29. Dust seal 30. Grommet 31. Steering wheel nut que of 25 ft.-lbs. (34 N*m) and adjust sector shaft end play as outlined in paragraph 7. Install new packing rings (3-Fig. 2) on adjusting screws, install flat washers (2) and tighten adjusting screw locknuts (1) while holding adjusting screws in proper position. Refill gear housing with Ford 134 gear lubricant to level of plug opening (ap- proximately 1.3 pints [0.61 liters]). When reinstalling steering arms, tighten retaining nuts (14) to a torque of 115-125 ft.-lbs. (156-170 N-m). POWER STEERING SYSTEM CAUTION: Absolute cleanliness of all parts Is of the utmost importance in the operation and servicing of the hydraulic power steering system. Of equal importance is the avoidance of nicks or burrs on any of the working parts. 10. FLUID AND BLEEDING. Recommended power steering fluid is Ford M2C41-A oil. Maintain fluid level at bottom of reservoir filler hole with tractor on level ground. Fluid and filter should be changed after each 600 hours of operation. The power steering system is self- bleeding. When unit has been disassembled, refill with new oil to full mark on dipstick, then start engine and cycle system several times by turning steering wheel from lock to lock. Recheck fiuid level and add as required. System is fully bled when no more air bubbles appear in reservoir as system is being cycled. 11. CHECKING SYSTEM PRESSURE AND FLOW. The power steering pump assembly incorporates a pressure relief valve and a fiow control valve. System relief pressure should be 600-700 psi (4140-4830 kPa) while fiow should be 2.7 gpm (10.26 liters/min.) at 1000 rpm on Models 2600, 3600 and 4100 and 2.5 gpm (9.5 liters/min.) at 1000 rpm on Models 2310, 2610, 3610 and 4110. To check system relief pressure, in- 9 13 23 Fig. 3- Cross-sectlonai view of manual steering gear assembly showing correct Installation of sector gears and wormshaft assembly. Refer to Fig. 2 for exploded view and parts Identification. 8

SHOP MANUAL Paragraphs 12-14 stall a **T" fitting in pressure line (19 - Fig. 4) at pump connection and con- nect a 0-1000 psi (0-7000 kPa) gage to fitting. With engine running at 1000 rpm and front wheels turned against lock, gage reading should be 600-700 psi (4140-4830 kPa). CAUTION: When checking system relief pressure, hold steering wheei against iock oniy iong enough to observe gage reading; pump may be damaged if steering wheei is held in this position for an excessive length of time. Pump must be disassembled to adjust opening pressure. Refer to paragraph 12 and Fig. 5. Shims (25) control system pressure and are available in thicknesses Fig. 4 —Drawing of power steering system on Models 2310, 2600, 2610, 3600, 3610, 4100 and 4110 without a cab. For exploded view of steering gear and vaive assembly (8), refer to Fig. 6. Exploded view of power steering pump (25> /5 shown in Fig. 5. 2. Steering cylinder, R.H. 7. Return tube 8. Steering gear & valve assy. 9. Front inner tube, L.H. 10. Rear outer tube, L.H. 11. Dust cover 12. Drag link assy. 13. Radius rod bEill spacer 14. Radius rod ball cap 15. Rear outer tube, R.H. 16. Front inner tube, R.H. 17. Drag link tube 18. Clamp 19. Pressure tube 20. Drag link front end 21. Dust seal 22. Steering arm 23. Radius rod 24. Steering cylinder, L.H. 25. Steering pump of 0.010 and 0.015 inch (0.254 and 0.381 mm). A change of 0.005 inch (0.127 mm) in total shim pack thickness will alter system pressure about 50 psi (345 kPa). 12. R&R AND OVERHAUL PUMP. Thoroughly clean pump, lines and surrounding area. Disconnect lines from pump and allow fiuid to drain. Cap all openings to prevent dirt from entering pump or lines, then unbolt and remove pump assembly from engine front plate. When reinstalling pump, use new seal- ing "0" ring and tighten retaining bolts to a torque of 26 ft.-lbs. (35 N-m). Reconnect lines, fill and bleed system as in paragraph 10. Refer to Fig. 5 for an exploded view of Fig. 5 — Exploded view of power steering pump with integral reservoir. 1. Bolt 2. Reservoir 3. Filter 4. Gasket 5. Through-bolt 6. Cover 7. "0" ring 8. Seal ring 9. Bearing block 10. Driven gear 11. Follow gear 12. Woodruff key 13. Body 14. Outlet elbow 15. Ring dowel 16. Seal ring 17. Seal ring 18. Flange housing 19. Oil seal 20. Snap ring 21. "O"ring 22. Drive gear 23. Shaft nut 24. Valve body 25. Shim pack 26. Spring 27. Spring guide 28. Seal 29. Valve head 30. Valve seat 31. "Oaring 32. Relief valve 32 pump and reservoir. Clean pump and surrounding area and disconnect pump pressure and return lines. Remove two cap screws securing pump to engine front cover and lift off pump and reservoir as a unit. Drain reservoir and remove through-bolt (1), reservoir (2) and filter (3). Relief valve cartridge (32) can now be removed if service is indicated. For ac- cess to shims (25), grasp seat (30) lightly in a protected vise and unscrew body (24). Shims (25) are available in thicknesses of 0.010 and 0.015 inch (0.254 and 0.381 mm). Starting with removed shim pack, substitute shims thus varying total pack thickness, to adjust opening pressure. Available shims permit thickness adjustment in increments of 0.005 inch (0.127 mm) and each 0.005 inch (0.127 mm) in shim pack thickness will change opening pressure about 50 psi (345 kPa). If parts are renewed, correct thickness can only be determined by trial and error, using removed shim pack as a guide. To disassemble pump, bend back tab washer and remove shaft nut (23), drive gear (22) and key (12). Mark or note relative positions of fiange housing (18), pump body (13) and cover (6); then remove pump through-bolts (5). Keep parts in their proper relative position when disassembling pump unit. Pump gears (10 and 11) are available in a matched set only. Bearing blocks (9) are available separately but should be renewed in pairs if renewal is necessary because of wear. Bearing blocks should also be renewed with gear set if any shaft or bore wear is evident. When reassembling pump, tighten through-bolts (5) to 15 ft.-lbs. (20 N-m) and drive gear nut (23) to 58 ft.-lbs. (78 N-m). 13. CONTROL VALVE AND STEERING GEAR ASSEMBLY. The power steering system is linkage booster type which utilizes a control valve combined with steering shaft and gear assembly as an integral unit. Refer to Fig. 6 for an exploded view of assembly. Adjustment and service infor- mation for unit is contained in the following paragraphs 14 through 18. 14. ADJUST STEERING GEAR. The steering wormshaft (21-Fig. 6) is carried in needle roller bearings (20 and 22) which require no adjustment. End thrust of wormshaft is utilized to operate control valve spool. To adjust sector gears, loosen locknuts (1) and back both adjusting screws (8) out two full turns. Turn adjusting screw on rear sector shaft (13) in until there is no perceptible backlash of rear sector shaft gears. Tighten locknut 9

Paragraphs 15-17 while holding adjusting screw in this position. With rear sector shaft adjusted, turn adjusting screw on front sector shaft (9) in until there is no perceptible backlash of front sector shaft gears, then tighten locknut while holding adjusting screw in this position. 15. R&R STEERING GEAR AND CONTROL VALVE ASSEMBLY. Remove steering gear by disconnecting oil lines and using procedure outlined in paragraph 8. To reinstall steering gear assembly, reverse removal procedure. Refill and bleed power steering system as outlined in paragraph 10. Refill steering gear with Ford 134 oil. 16. RENEW CONTROL VALVE UPPER SEAL. If power steering fiuid leaks from steering column housing, the control valve upper seal (40-Fig. 6) is leaking and can be renewed as follows: Follow general procedures outlined in paragraph 15, except that fuel lines do not need to be disconnected nor does fuel tank need to be removed. Thoroughly clean steering gear and control valve assembly. Remove cap screws retaining steering column (41) to steering gear and remove steering column. Remove seal from lower end of steering column with a suitable puller. Drive bushing (42) from upper end of steering column with a 1-inch (25.4 mm) diameter dowel. n ' Fig. 6 — Exploded view of power steering gear and vaive assembiy. Turning effort on steering wheel, or reaction of front wheels through steering linkage and gears, causes wormshaft (21) to move up or down, thereby actuating the control valve (27). 1. Locknut 17. Felt dust seal 2. Washer 18. Oil seal ^^• 4. Side covers 19. Paper gasket (0.005 in.) «g 37. Preload spring 39. "O" ring 40. Oil seal 41. Steering column 42. Upper bushing 45. Steering wheel nut 7. Shim 8. Adjusting screw 9. Sector gear, single 10. Steering arm, L.H. 11. Housing 12. Oil lever &fillerplug 13. Sector gear, double 14. Nut 15. Washer 16. Steering arm, R.H. 22. Needle roller bearing 23. Adapter assy. 24. Oil seal 25. "O"ring 26. Thrust bearing assy. 27. Valve assy. 28. Tube seat 29. Reaction plungers (2) 30. Thrust plungers (6) 31. Tube seat FORD Install new seal in lower end of steering column using a 1% inch (34.9 mm) diameter driver. Install seal so spring and lip will be downward (towards control valve). Tighten steering column retaining cap screws to a torque of 25 ft.-lbs. (34 N-m) and remove seal guide. Install new bushing in top end of steering column, then reinstall removed parts. Refill and bleed power steering as outlined in paragraph 10. 17. OVERHAUL CONTROL VALVE. With steering gear and control valve assembly removed from' tractor as outlined in paragraph 15 proceed as follows: Scribe a line across steering column, valve housing and adapter to facilitate reassembly. Remove return line union (33-Fig. 6) from valve housing, discard "0" ring (32) and unscrew check valve (34). Remove cap screws retaining steering column and remove column from steering shaft. Carefully unstake locknut (38) and temporarily install steering wheel on shaft to hold shaft while unscrewing nut. Remove steering wheel and nut and position steering gear unit on bench so steering shaft is in horizontal position. Slide spring washer (37), upper thrust bearing (36), control valve assembly (27) and lower thrust bearing (26) from steering shaft. NOTE: Take care that control valve spool, plungers (30) and check vaives (29) do not drop out of vaive housing as it is removed from steering shaft. Unboit and remove adapter (23) from steering gear housing. Note which end of control valve spool has the identification groove (Fig. 9), then slide spool from housing. Remove the six plungers (30-Fig. 6), three Fig. 7—Cross-sectional view of steering gear assembly showing correct Installation (timing) of sector gears and wormshaft; refer to Fig. 6 for exploded view of unit and for parts Identifica- tion. 10

SHOPMANAUL Paragraph 18 CHECK VALVE CONTROL VALVE PLUNGERS Fig. 8 — View showing upper side of control valve and spool assembly; install the three sets of control valve plungers and springs and the two check vaives in the bores In housing as shown. CONTROL VALVE HOUSING shoulder on shaft. Lubricate valve spool and insert in housing with identifying groove in same direction as when removed. Insert check valves in same bore from which they were removed and with open ends inward. Lubricate and insert the six plungers in the remaining bores with a spring between each set of plungers. Carefully place the assembled valve unit on steering shaft next to thrust bearing with the offset cylinder ports down as shown in Fig. 10. Place large race of upper thrust bearing on shaft against valve, then install bearing retainer and small race. Place spring washer on shaft against small thrust bearing race with cup side of washer towards the race. Install new locknut. Tighten nut so all end play is removed, then loosen nut 1/6-turn and stake nut to locating slot in steering shaft as shown in Fig. 10. Complete remainder of assembly by reversing disassembly procedure. springs (35) and two check valves (29), noting which hole contained check valves. If any of the brass seats (28 and/or 31) for pump pressure line and Fig. 9—Insert control valve spool In housing so identification groove (G) will be towards bottom end of steering shaft. \ steering cylinder lines are damaged, remove them from valve housing by threading a tap into the seat, clamping tap in a vise and pulling housing from seat. Remove seal (40) and bushing (42) from steering column. Remove seal (24) from adapter (23). Inspect all removed parts for damage or undue wear and renew any not accep- table for further service. Install new "0" rings (25, 32 and 39), seals (24 and 40) and locknut (38) when reassembling. To reassemble, proceed as follows: To reassemble control valve, install new seal (24) in adapter (23) with lip of seal up (towards control valve). Install a new 0.005 inch (0.127 mm) thick paper gasket (19) on steering gear housing, then slide adapter over steering shaft and tighten retaining nuts to a torque of 25 ft.-lbs. (34 N-m). Place new "0" ring (25) in groove in top of adapter. Place small race, bearing retainer and large race over steering shaft and against SLOT Fig. 10-When valve retaining nut is properly posi- tioned as explained in text; stake nut to slot in shaft as shown. 18. OVERHAUL STEERING GEAR. With control valve assembly and adapter removed from top of steering gear as outlined in paragraph 17, refer to Fig. 6 and proceed as follows: Remove nuts (14) and with suitable pullers, remove steering arms (10 and 16). Remove locknuts (1) from sector shaft adjusting screws (8) and remove cap screws retaining side covers (4) to steering gear housing. With screw- driver, turn adjusting screws in to push side covers from sector shafts and steering gear housing. Withdraw sector shafts (9 and 13) and adjusting screws from housing. Remove steering shaft and ball nut assembly (21). Drive seals (18) from steering gear housing. Carefully inspect all parts and renew any that are damaged or show excessive wear. Sector shaft bushings in steering gear housing are not serviced separately from housing. Bushings (5) are renewable. Steering shaft and ball nut assembly is serviced as a complete unit only. Renew needle bearings (20 and 22) in steering gear housing and adapter if loose or worn; drive or press on lettered (trade mark) end of bearing cage only. Reassemble unit as follows: Install seals (18) in gear housing with lips of seals to inside. Install new seals (24) in adapter (23) with lip of seal upward (toward control valve). Place steering shaft and ball nut assembly in gear housing with gear teeth on ball nut forward, thefi install adapter with a new 0.005 inch (0.127 mm) thick paper gasket (19). NOTE: Take care not to damage seai in adapter when installing adapter over steering shaft; wrap threads, sharp shouiders, etc., with piastic tape. 11

Ford 4100 Tractor Workshop Service Repair Manual

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