New Holland TC35/TC35D/TC40/TC40D/TC45/TC45D Tractors Service & Repair Manual

SECTION 00 - GENERAL INFORMATION BOOK 1 Chapter 1 - General Information CONTENTS Section Description Page 00 000 Introduction 00-2 ................................................................ Safety 00-3 ..................................................................... Technical Information 00-4 ........................................................ Safety Precautions 00-5 .......................................................... Safety Decals - TC35, 40, 45 00-8 ................................................. Instruction Decals - TC35, 40, 45 00-9 .............................................. Safety Decals - TC35D, 40D, 45D 00-12 ............................................ Instruction Decals - TC35D, 40D, 45D 00-13 ......................................... International Symbols 00-17 ....................................................... Specifications - TC35, 40, 45 00-18 ................................................ General Dimensions - TC35, 40, 45 00-25 ........................................... Specifications - TC35D, 40D, 45D 00-31 ............................................ General Dimensions - TC35D, 40D, 45D 00-37 ...................................... Minimum Hardware Tightening Torques 00-41 ....................................... Special Tools 00-43 .............................................................. Lubricants 00-44 ................................................................. 00 400 Recommended Lubricants 00-44 ................................................... Adjustments 00-45 ............................................................... Tire Inflation Pressure - Adjustments 00-45 .......................................... 00 100 Pre-Season and Pre-Delivery Checklist 00-46 .......................................

SECTION 10 - ENGINE BOOK 1 Chapter 1 - Engine CONTENTS Section Description Page Specifications 10-3 ............................................................... Metric Bolt Torque Specifications 10-12 ............................................. Special Tools 10-13 .............................................................. General Information 10-15 ........................................................ Description of Operation 10-15 .................................................... Troubleshooting 10-16 ............................................................ 10 101 Cylinder Head Removal 10-53 ..................................................... 10 106 Timing Gears and Camshaft Removal 10-57 ......................................... 10 102 Oil Sump Removal 10-58 ......................................................... 10 110 Balancer Assembly-Removal 10-59 ................................................ 10 105 Connecting Rods, Bearings, and Pistons, Rings Removal 10-59 ........................ 10 103 Flywheel 10-60 .................................................................. Disassembly, Inspection, Fits, Clearances, and Assembly of Component Assemblies 10-61 .......................................... 10 101 Cylinder Head Disassembly 10-61 ................................................. 10 105 Pistons, Piston Rings, and Connecting Rods Disassembly and Inspection 10-67 .......... 10 103 Crankshaft 10-72 ................................................................ 10 106 Timing Gear 10-76 ............................................................... 10 103 Flywheel 10-77 .................................................................. 10 102 Timing Gear Housing 10-78 ....................................................... Engine Reassembly 10-79 ........................................................ 10 103 Crankshaft and Bearing Holder Reassembly 10-79 ................................... 10 105 Pistons and Connecting Rods 10-80 ................................................ 10 110 Balancer Assembly-Installation 10-81 ............................................... 10 106 Timing Gear Cover, TIming Gears, and Camshaft Assembly 10-82 ...................... 10 106 Idler Gear, Oil Pump, and Injection Timing 10-83 ..................................... 10 101 Head Gasket Selection 10-86 ...................................................... 10 106 Valve Clearance Adjustment 10-87 ................................................. 10 218 Fuel Piping 10-89 ................................................................ Engine Lubrication System 10-91 .................................................. 10 304 Engine Lubrication System - Description of Operation 10-91 ........................... 10 218 Fuel Piping 10-91 ................................................................ 10 206 Oil Filter 10-95 ..................................................................

10 304 Oil Pump 10-95 .................................................................. Cooling System 10-99 ............................................................ 10 400 Cooling System - Description of Operation 10-99 ..................................... 10 402 Thermostat 10-102 .............................................................. 10 402 Water Pump 10-102 ............................................................. 10 414 Cooling Fan 10-102 ............................................................. Cooling System Overhaul 10-103 ................................................. 10 406 Radiator 10-103 ................................................................ 10 402 Water Pump Removal 10-105 ..................................................... 10 402 Thermostat Removal 10-108 ..................................................... SECTION10 -- ENGINE BOOK 1 Chapter 2 -- Fuel Systems CONTENT Section Description Page Specifications 10-112 ............................................................. Torque Specifications 10-113 ...................................................... Special Tools 10-113 ............................................................. 10 242 Description of Operation 10-114 ................................................... Troubleshooting 10-116 ........................................................... 10 244 Fuel Variation Mechanism 10-121 ................................................. 10 244 CTD (Compact Timing Device) 10-122 ............................................. 10 236 Pumping Elements 10-124 ....................................................... 10 214 Delivery Valves 10-126 .......................................................... 10 242 Injection Pump Removal 10-128 .................................................. 10 230 Timing and Governor Adjustments 10-131 .......................................... Spill-Timing Procedure 10-132 .................................................... Auto Bleed 10-137 .............................................................. Bleeding to Fuel System 10-138 .................................................. Fuel Scre/High Idle Adjustment 10-138 ............................................. 10 230 Governor Operation 10-139 ...................................................... 10 218 Injectors 10-145 ................................................................

SECTION 18 - CLUTCH BOOK 1 Chapter1 -- Clutch CONTENTS Section Description Page 18 000 Specifications 18-2 ............................................................... Bolt Torque Specifications 18-3 .................................................... Special Tools 18-3 ............................................................... Description of Operation 18-4 ..................................................... Troubleshooting 18-6 ............................................................. Overhaul 18-7 ................................................................... 18 110 Clutch Removal 18-13 ............................................................ 18 110 Clutch Installation 18-14 .......................................................... 18 110 Clutch Related Components 18-21 ................................................. Clutch Linkage Components 18-24 ................................................. 18 100 Clutch Cross Shaft Bushings 18-24 ................................................. Clutch Pedal Adjustments 18-27 ................................................... Clutch Pedal Maximum Travel Adjustment 18-27 .....................................

SECTION 21 -- TRANSMISSION BOOK 1 Chapter 1 -- 12 x 12 Synchronized Shuttle Shift Gear Transmission CONTENT Section Description Page Specifications 21-2 ............................................................... Metric Bolt Torque Specifications 21-3 .............................................. Special Tools 21-4 ............................................................... 21 000 Description of Operation 21-5 ..................................................... Powerflow 21-8 .................................................................. Troubleshooting 21-12 ............................................................ Overhaul 21-13 .................................................................. 21 110 10 Overhaul - Removal 21-13 ........................................................ 21 114 Separating at the Clutch Housing/Engine 21-13 ...................................... Clutch Housing Disassembly 21-19 ................................................. 21 148 63 Retainer Cover 21-23 ............................................................ 21 148 63 Main Shift Rails and Shift Forks 21-24 .............................................. 21 148 63 Main Shaft 21-27 ................................................................ 21 148 63 Range Shift Rail and Shift Fork 21-30 .............................................. 21 148 63 Range Gear Countershaft 21-31 ................................................... 21 148 63 Input Shaft 21-32 ................................................................ 21 148 63 Reverse Idler Shaft 21-33 ......................................................... 21 148 63 Shuttle Shift Rail and Fork 21-35 ................................................... 21 148 63 Main Countershaft 21-36 .......................................................... 21 148 63 Synchronizers 21-38 ............................................................. 21 148 63 Input Shaft 21-45 ................................................................ 21 148 63 Main Countershaft End Float 21-46 ................................................. 21 148 63 Range Gear Countershaft 21-46 ................................................... 21 148 63 Range Shift Rail and Fork 21-47 ................................................... 21 148 63 Main Shaft 21-48 ................................................................ 21 148 63 Main Shaft End Float 21-51 ....................................................... 21 110 10 Clutch Housing 21-56 ............................................................ 21 130 Transmission Shift Levers 21-67 ...................................................

SECTION 23 - DRIVELINE BOOK 1 Chapter 1 -- Driveline CONTENTS Section Description Page 23 000 Bolt Torque Specifications 23-2 .................................................... Special Tools 23-3 ............................................................... Description of Operation 23-4 ..................................................... Front Wheel Drive Take Off Gearbox 23-4 ........................................... Sensitrack 23-5 ................................................................. Troubleshooting 23-9 ............................................................. Lubrication 23-9 ................................................................. Overhaul 23-10 .................................................................. Front Wheel Drive Take Off Gearbox 23-10 .......................................... 23 260 Sensitrack Removal 23-14 ........................................................ 23 260 Sensitrack Installation 23-31 .......................................................

SECTION 25 - 4WD FRONT AXLE, SUPERSTEERt AND SENSITRACKt BOOK 2 Chapter 1 - 4WD Front Axle, Supersteert and Sensitrackt CONTENTS Section Description Page Specifications 25-3 ............................................................... Bolt Torque Specifications 25-6 .................................................... Special Tools 25-6 ............................................................... 25 000 Description of Operation 25-7 ..................................................... 4WD Front Axle 25-7 ............................................................. Troubleshooting 25-8 ............................................................. Lubrication 25-10 ................................................................ Overhaul 25-11 .................................................................. 25 108 Disassembly 25-12 ............................................................... 25 102 Front Axle and Differential 25-15 ................................................... Drive Pinion Diassembly 25-16 .................................................... Drive Pinion Inspection 25-17 ...................................................... Drive Pinion Assembly 25-18 ...................................................... Differential Gear Assembly 25-18 .................................................. Axle and Differential Assembly 25-19 ............................................... Differential Case Bearing Preload Check and Adjustment 25-20 ........................ Ring Gear-to-Pinion Backlash Check and Adjustment 25-20 ........................... 25 108 Gear Reduction Box Assembly 25-23 ............................................... Ring Gear-to-Pinion Backlash Check and Adjustment 25-25 ........................... Bevel Gear-to-Pinion Backlash Check 25-26 ......................................... 25 100 Supersteert 25-27 .............................................................. Supersteert Front Axle 25-30 ................................................... Overhaul 25-33 .................................................................. 25 100 Supersteert Axle Removal 25-35 .................................................. Gear Reduction-Drop Box Disassembly 25-40 ....................................... 25 102 Front Axle and Differential Disassembly 25-42 ....................................... Drive Pinion Disassembly 25-43 ................................................... Inspection 25-44 ................................................................. Drive Pinion Assembly 25-45 ...................................................... Differential Gear Assembly 25-45 .................................................. 25 102 Axle and Differential Assembly 25-46 ...............................................

Differential Case Bearing Preload Check and Adjustment 25-47 ........................ Ring Gear-to-Pinion Backlash Check and Adjustment 25-47 ........................... 25 108 Gear Reduction Box Assembly 25-50 ............................................... Bevel Gear-to-Pinion Backlash Check 25-52 ......................................... Supersteert Axle Installation 25-53 ................................................ SECTION 27 - DIFFERENTIAL, REAR AXLE BOOK 2 Chapter 1 -- Differential, Rear Axle CONTENTS Section Description Page 27 000 Specifications 27-2 ............................................................... Bolt Torque Specifications 27-3 .................................................... Special Tools 27-3 ............................................................... Description of Operation 27-4 ..................................................... 27 110 Differential 27-5 ................................................................. 27 110 Differential Lock 27-5 ............................................................. 27 126 Rear Axle 27-6 .................................................................. 27 106 Differential Overhaul 27-7 ......................................................... 27 126 Rear Axle Overhaul 27-16 ........................................................ 27 126 Final Pinion Overhaul 27-25 .......................................................

SECTION 29 -- HYDROSTATIC TRANSMISSION BOOK 2 Chapter 1 -- Hydrostatic Transmission CONTENT Section Description Page Specifications 29-2 ............................................................... Metric Bolt Torque Specifications 29-4 .............................................. Special Tools 29-4 ............................................................... 29 202 Description of Operation 29-5 ..................................................... 29 212 Variable Displacement Pump Operation 29-11 ....................................... 29 212 Two Position Displacement Motor Operation 29-12 ................................... 29 134 Hi/Lo Speed Control/Control Pod 29-13 ............................................. 29 200 Foot Control Pedals 29-13 ........................................................ Troubleshooting 29-16 ............................................................ Pressure Testing and Adjustments 29-19 ............................................ Separating the Tractor 29-23 ...................................................... TC35D, TC40D, and TC45D w/HST Transmission 29-23 .............................. 29 202 Hydrostatic Transmission Disassembly 29-44 ........................................ 29 130 Port Block Removal 29-47 ........................................................ 29 218 Cylinder Block Assembly for Pump 29-50 ........................................... 29 218 Cylinder Block Assembly for Motor 29-51 ............................................ 29 130 Port Block Assembly 29-52 ........................................................ 29 204 Check Valve 29-54 ............................................................... 29 300 Hydrostatic Transmission Gearbox 29-55 ........................................... Gearbox Identification 29-56 ....................................................... 29 214 Hi/Lo Solenoid Valve Assembly 29-68 .............................................. Cruise Control 29-76 ............................................................. Electromagnet Air Gap Adjustment 29-77 ........................................... 29 200 HST Foot Control Pedals Neutral Adjustment 29-78 ..................................

SECTION 31 -- POWER TAKE-OFF (PTO) SYSTEMS BOOK 2 Chapter 1 -- Power Take-Off (PTO) Systems CONTENT Section Description Page Specifications 31-2 ............................................................... Metric Bolt Torque Specifications 31-3 .............................................. Special Tools 31-4 ............................................................... 31 000 Description of Operation 31-5 ..................................................... 31 110 Rear PTO-Power Flow Diagram -- 12x12 Synchronized Shuttle Shift Transmission 31-6 ... 31 110 Rear PTO-Power Flow Diagram -- Hydrostatic Transmission (HST) 31-7 ................. 31 120 Mid PTO-Power Flow Diagram -- Tractors Equipped with a Mid PTO Kit 31-8 ............. 31 104 Hydraulic Fluid Flow to the PTO Clutch Assembly 31-9 ................................ Troubleshooting 31-12 ............................................................ Pressure Testing 31-13 ........................................................... 31 104 82 Overhaul 31-15 .................................................................. 31 104 82 PTO Clutch Control Valve 31-18 ................................................... 31 114 62 PTO Clutch Assembly 31-23 ...................................................... 31 114 68 PTO Clutch Disassembly 31-26 .................................................... 31 114 62 PTO Clutch Installation 31-34 ...................................................... 31 114 42 PTO System Overhaul -- 12x12 Synchronized Shuttle Shift Transmission 31-38 .......... 31 114 46 PTO Countershaft and Rear PTO Shaft 31-40 ....................................... 31 114 46 Countershaft Disassembly 31-42 ................................................... 31 114 00 PTO System Overhaul -- Hydrostatic Transmission (HST) -- Removal 31-47 .............. 31 114 42 PTO Input Shaft 31-47 ............................................................ 31 114 46 PTO Countershaft and Rear PTO Shaft 31-49 ....................................... 31 114 42 PTO Countershaft and Rear PTO Shaft -- Disassembly 31-53 .......................... 31 114 19 PTO Countershaft and Rear PTO Shaft -- Installation 31-57 ............................ 31 120 00 Mid PTO Countershaft and Drop Box Overhaul 31-60 .................................

New Holland TC35/TC35D/TC40/TC40D/TC45/TC45D Tractors Service & Repair Manual

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