John Deere TeamMateII 1200/1400/1600 Series Inboard Planetary Axles Workshop Service Repair Manual

COMPONENT TECHNICAL MANUAL John Deere Waterloo Works CTM43 (09JAN98) LITHO IN U.S.A. ENGLISH TeamMate® II 1200, 1400, and 1600 Series Inboard Planetary Axles

TeamMate™II 1200, 1400, and 1600 Series Inboard Planetary Axles John Deere Waterloo Works CTM43 (18FEB98) LITHO IN U.S.A. ENGLISH

TeamMate™II 1200-1400-1600 Axles CTM43 (18FEB98)

FOREWORD This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. N This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. See the machine technical manual for information on component removal and installation, and gaining access to the components. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. This component technical manual covers the recommended repair procedure for the TeamMate™II 1200, 1400, and 1600 Series Inboard Planetary Axles. Some components from these axles, such as axle housings, brakes, and input quills, may be serviced without removing the complete axle assembly from the machine. You may have to determine this procedure yourself for a safe removal of such components. See information to remove and install the complete axle assembly, found in your vehicle technical manual. Clean differential and axle assemblies before servicing. Always work in a clean work area. Binders, binder labels, and tab sets can be ordered by John Deere dealers direct from the John Deere Distribution Service Center. This manual is part of a total product support program. FOS MANUALS—REFERENCE TECHNICAL MANUALS—MACHINE SERVICE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians. RX,CTM43,IFC -19-07JAN98 Introduction CTM43 (18FEB98) 1200, 1400, 1600 TeamMate II Axles 180298 PN=3

NOTICE TO THE DEALER This Component Technical Manual should be used for the repair of John Deere TeamMate™II 1200, 1400, and 1600 Series Inboard Planetary Axles. IMPORTANT: Before beginning repair or making adjustments, become familiar with Axle Identification and the Axle Serial Number Plate. (See General—Group 10.) Discard CTM43 dated 31JAN95 RX,CTM43,DLR -19-05DEC97 Introduction CTM43 (18FEB98) 1200, 1400, 1600 TeamMate II Axles 180298 PN=4

Introduction CTM43 (18FEB98) 1200, 1400, 1600 TeamMate II Axles 180298 PN=5

Page Group 05—Safety Group 10—General General Specifications . . . . . . . . . . . . . . . . 10-1 Axle Identification . . . . . . . . . . . . . . . . . . . . 10-2 Serial Number Identification John Deere . . . . . . . . . . . . . . . . . . . . . . 10-2 OEM—1200 Series . . . . . . . . . . . . . . . . . 10-3 OEM—1400 Series . . . . . . . . . . . . . . . . . 10-4 OEM—1600 Series . . . . . . . . . . . . . . . . . 10-5 General Repair Procedures . . . . . . . . . . . . . 10-6 Sealants and Adhesives Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Sealing Instructions . . . . . . . . . . . . . . . . . . 10-9 Axle Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Service and Maintenance Schedule . . . . . 10-11 Drain and Refill . . . . . . . . . . . . . . . . . . 10-12 Alternative and Synthetic Lubricants . . . . . 10-12 Lubricant Storage . . . . . . . . . . . . . . . . . 10-13 Mixing of Lubricants . . . . . . . . . . . . . . . 10-13 Bolt Torque Charts . . . . . . . . . . . . . . . . . . 10-14 Hydraulic Connections . . . . . . . . . . . . . . . 10-16 Group 15—1200-1400 Oscillation Supports Essential or Recommended Tools . . . . . . . . . 15-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 15-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 15-2 Dual Input Oscillating Supports Exploded View . . . . . . . . . . . . . . . . . . . . 15-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Disassemble and Inspect . . . . . . . . . . . . . 15-4 Assemble . . . . . . . . . . . . . . . . . . . . . . . 15-5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Opposite End Oscillating Support . . . . . . . . 15-6 Group 16—1600 Oscillation Supports Essential or Recommended Tools . . . . . . . . . 16-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 16-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 16-2 Page Dual Input Oscillating Supports Cross-Sectional View . . . . . . . . . . . . . . . . 16-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . 16-3 Disassemble . . . . . . . . . . . . . . . . . . . . . 16-3 Assemble . . . . . . . . . . . . . . . . . . . . . . . 16-4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8 Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . 16-9 Opposite End Oscillating Support . . . . . . . . 16-9 Group 17—Axle Assembly End Play Specifications . . . . . . . . . . . . . . . . . . . . . . 17-1 Adjust End Play . . . . . . . . . . . . . . . . . . . . . 17-2 Group 20—1200-1400 Input Housing/Case Cover Essential or Recommended Tools . . . . . . . . . 20-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 20-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 20-2 Input Housing Remove and Install . . . . . . . . . . . . . . . . . 20-3 Cross-Sectional and Exploded Views . . . . . 20-4 Disassemble and Assemble . . . . . . . . . . . 20-6 Determine Cone Point Shim Pack . . . . . . . 20-8 Continue Assembly . . . . . . . . . . . . . . . . . 20-9 Adjust Pinion Shaft End Play . . . . . . . . . 20-11 Group 21—1600 Input Housing/Case Cover Essential or Recommended Tools . . . . . . . . . 21-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 21-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 21-2 Install Axle in Repair Stand . . . . . . . . . . . . . 21-3 Input Housing/Cover Remove . . . . . . . . . . . . . . . . . . . . . . . . 21-4 Cross-Sectional and Exploded Views . . . . . 21-5 Disassemble . . . . . . . . . . . . . . . . . . . . . 21-7 Assemble . . . . . . . . . . . . . . . . . . . . . . . 21-9 Determine Cone Point Shim Pack . . . . . . 21-10 Continue Assembly . . . . . . . . . . . . . . . . 21-11 Install . . . . . . . . . . . . . . . . . . . . . . . . . 21-14 Continued on next page COPYRIGHT© 1998 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION® Manual Previous Editions Copyright 1995, 1992, 1991 Deere & Company All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. CTM43-19-18FEB98 Contents CTM43 (18FEB98) i 1200, 1400, 1600 TeamMate II Axles 180298 PN=326 05 10 15 16 17 20 21 25 30 31 32 35 36 37 38

Page Group 25—Disconnect and Input Housing/Case Cover Essential or Recommended Tools . . . . . . . . . 25-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 25-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 25-2 Axle Disconnect and Input Housing Cross-Sectional View . . . . . . . . . . . . . . . . 25-3 Axle Disconnect Cross-Sectional and Exploded Views . . . . . 25-4 Remove, Disassemble, and Assemble . . . . 25-5 Input Housing/Case Cover Cross-Sectional and Exploded Views . . . . . 25-9 Remove . . . . . . . . . . . . . . . . . . . . . . . 25-10 Disassemble . . . . . . . . . . . . . . . . . . . . 25-10 Assemble . . . . . . . . . . . . . . . . . . . . . . 25-13 Determine Cone Point Shim Pack . . . . . . 25-14 Continue Assembly . . . . . . . . . . . . . . . . 25-15 Adjust Pinion Shaft . . . . . . . . . . . . . . . . 25-17 Install Axle Disconnect . . . . . . . . . . . . . . . 25-18 Group 30—1200-1400 Differential Housings Essential or Recommended Tools . . . . . . . . . 30-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 30-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 30-3 Exploded and Cross-Sectional Views Differential Lock Lines (Air Boost System) . . . . . . . . . . . . . . . . . . . . . . . 30-5 Differential Lock lines (Suction Tube) . . . . . 30-6 1200 Differential Lock—Capture System. . . . 30-7 1400 Differential Lock—Capture System. . . . 30-8 1200 Differential Lock—Air Boost System . . . . . . . . . . . . . . . . . . . . . . . 30-10 1400 Differential Lock—Air Boost System . . . . . . . . . . . . . . . . . . . . . . . 30-11 Differential Housing Assembly Remove . . . . . . . . . . . . . . . . . . . . . . . 30-13 Disassemble, Inspect, and Assemble . . . . 30-14 Assemble and Test Differential Lock Quill . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 Ring Gear . . . . . . . . . . . . . . . . . . . . . . 30-21 Differential Pinions . . . . . . . . . . . . . . . . 30-22 No-Spin Differential Housing Assembly Cross-Sectional and Exploded Views . . . . 30-25 Disassemble, Inspect, and Assemble . . . . 30-26 Install . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Differential Lock Lines . . . . . . . . . . . . . . . . 30-32 Adjust Differential Bearing Preload . . . . . . . . . . . 30-33 Differential Backlash . . . . . . . . . . . . . . . 30-34 Install Housing/Cover . . . . . . . . . . . . . . . . 30-35 Page Group 31—1400 John Deere Grader Differential Housing Essential or Recommended Tools . . . . . . . . . 31-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 31-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 31-3 Differential Case Assembly Install in Repair Stand . . . . . . . . . . . . . . . 31-4 Remove Input Housing/Cover . . . . . . . . . . 31-5 Differential Housing Assembly Cross-Sectional View . . . . . . . . . . . . . . . . 31-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . 31-7 Test Differential Lock Quill . . . . . . . . . . . . 31-8 Disassemble . . . . . . . . . . . . . . . . . . . . . 31-9 Remove and Install Ring Gear . . . . . . . . 31-14 Assemble . . . . . . . . . . . . . . . . . . . . . . 31-14 Install . . . . . . . . . . . . . . . . . . . . . . . . . 31-18 Adjust Differential Bearing Preload . . . . . . 31-19 Install Differential Lock Lines . . . . . . . . . . 31-20 Install Input Housing/Cover . . . . . . . . . . . . 31-20 Adjust Differential Backlash . . . . . . . . . . . . 31-21 Group 32—1600 Differential Housing Essential or Recommended Tools . . . . . . . . . 32-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 32-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 32-2 Install Axle in Repair Stand . . . . . . . . . . . . . 32-3 Differential Housing Assembly Remove . . . . . . . . . . . . . . . . . . . . . . . . 32-3 Cross-Sectional Views Differential Lock . . . . . . . . . . . . . . . . . . . 32-6 Standard Differential . . . . . . . . . . . . . . . . 32-7 Differential Housing Assembly Disassemble, Inspect, and Assemble . . . . . 32-8 Install . . . . . . . . . . . . . . . . . . . . . . . . . 32-15 Adjust Differential Preload . . . . . . . . . . . . . . . . 32-17 Differential Backlash . . . . . . . . . . . . . . . 32-18 Group 35—1200-1400 Axle Housing, Shaft, and Final Drive Essential or Recommended Tools . . . . . . . . . 35-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 35-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 35-2 Exploded Views Axle Shaft and Housing . . . . . . . . . . . . . . 35-3 Final Drive . . . . . . . . . . . . . . . . . . . . . . . 35-6 Remove Axle Housings . . . . . . . . . . . . . . . . 35-6 Axle Shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . 35-8 Disassemble, Inspect, and Assemble . . . . . 35-9 Continued on next page Contents CTM43 (18FEB98) ii 1200, 1400, 1600 TeamMate II Axles 180298 PN=327 05 10 15 16 17 20 21 25 30 31 32 35 36 37 38

Page Disassemble and Assemble Axle Housing . . 35-13 Planet Pinion Carrier and Axle Shaft Cross-Sectional View . . . . . . . . . . . . . . . 35-15 Planet Pinion Carrier Disassemble . . . . . . . . . . . . . . . . . . . . 35-17 Inspect . . . . . . . . . . . . . . . . . . . . . . . . 35-17 Assemble . . . . . . . . . . . . . . . . . . . . . . 35-18 Assemble Axle Shaft and Housing . . . . . . . 35-19 Adjust Axle Bearings . . . . . . . . . . . . . . . . 35-21 Install Axle Housing . . . . . . . . . . . . . . . . . 35-25 Fill Axle Housing with Grease . . . . . . . . . . 35-27 Group 36—1400 John Deere Grader Planetary Carrier Essential or Recommended Tools . . . . . . . . . 36-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 36-1 Planet Pinion Carrier Cross-Sectional View . . . . . . . . . . . . . . . . 36-2 Disassemble . . . . . . . . . . . . . . . . . . . . . 36-3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 36-4 Assemble . . . . . . . . . . . . . . . . . . . . . . . 36-5 Inspect and Install Final Drive Ring Gear . . . . 36-5 Group 37—1400 John Deere Skidder Planetary Carrier Other Material . . . . . . . . . . . . . . . . . . . . . . 37-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 37-1 Planet Pinion Carrier Cross-Sectional View . . . . . . . . . . . . . . . . 37-2 Disassemble, Inspect, and Assemble . . . . . 37-3 Group 38—1600 Final Drive/Planetary Carrier Essential or Recommended Tools . . . . . . . . . 38-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 38-3 Specifications . . . . . . . . . . . . . . . . . . . . . . 38-3 Install Axle in Repair Stand . . . . . . . . . . . . . 38-4 Final Drive Assemblies Remove . . . . . . . . . . . . . . . . . . . . . . . . 38-5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 38-6 Final Drive and Axle Cross-Sectional and Exploded Views . . . . . . . . . . . . . . . . . . . 38-8 Final Drive Disassemble . . . . . . . . . . . . . . . . . . . . 38-12 Exploded View—Planetary Carrier . . . . . . 38-14 Planet Pinion Carrier Disassemble . . . . . . . . . . . . . . . . . . . . 38-15 Inspect . . . . . . . . . . . . . . . . . . . . . . . . 38-16 Assemble . . . . . . . . . . . . . . . . . . . . . . 38-17 Axle Housing Remove . . . . . . . . . . . . . . . . . . . . . . . 38-18 Disassemble and Assemble . . . . . . . . . . 38-18 Page Axle Shaft Disassemble, Inspect, and Assemble . . . . 38-20 Install Axle Housing . . . . . . . . . . . . . . . . . 38-25 Adjust Axle Bearings . . . . . . . . . . . . . . . . 38-26 Group 40—1200-1400 Single Disk Brakes Essential or Recommended Tools . . . . . . . . . 40-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 40-1 Brakes Exploded Views . . . . . . . . . . . . . . . . . . . 40-2 Disassemble and Assemble Brakes . . . . . . 40-4 Group 41—1600 Single Disk Brakes Specifications . . . . . . . . . . . . . . . . . . . . . . 41-1 Brakes Cross-Sectional and Exploded Views . . . . . 41-2 Disassemble and Assemble . . . . . . . . . . . 41-3 Group 42—1400 Multiple Disk Brakes Essential or Recommended Tools . . . . . . . . . 42-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 42-1 Brakes Inspection . . . . . . . . . . . . . . . . . . . . . . . 42-1 Cross-Sectional and Exploded Views . . . . . 42-2 Remove and Install . . . . . . . . . . . . . . . . . 42-4 Vacuum Leakdown Test . . . . . . . . . . . . . . 42-5 Group 43—Parking Brake Essential or Recommended Tools . . . . . . . . . 43-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 43-1 Manual Park Brake Cross-Sectional View . . . . . . . . . . . . . . . . 43-2 Remove, Assemble, and Adjust . . . . . . . . . 43-3 Spring Applied Hydraulic Release Brake Cross-Sectional View . . . . . . . . . . . . . . . . 43-4 Remove, assemble and Adjust . . . . . . . . . 43-5 Group 45—Dry Drum Brake Specifications . . . . . . . . . . . . . . . . . . . . . . 45-1 Brake Drum Description . . . . . . . . . . . . . . . . . . . . . . . 45-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . 45-3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 45-4 Remove Brake Adjuster . . . . . . . . . . . . . . . 45-5 Camshaft and Air Chamber Bracket Remove . . . . . . . . . . . . . . . . . . . . . . . . 45-7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 45-7 Spider Assembly Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 45-8 Remove and Install . . . . . . . . . . . . . . . . . 45-8 Continued on next page Contents CTM43 (18FEB98) iii 1200, 1400, 1600 TeamMate II Axles 180298 PN=328 40 41 42 43 45 100 105 110 115 120 499 INDX

Page Install Air Chamber Bracket and Camshaft . . . . . . 45-9 Brake Adjuster . . . . . . . . . . . . . . . . . . . 45-10 Brake Drum . . . . . . . . . . . . . . . . . . . . . 45-11 Group 100—Troubleshooting Troubleshoot Axle and Differential . . . . . . . . 100-1 Group 105—Brake Inspection, Adjustments, Tests, and Bleeding Park Brake—Spring Applied/Hydraulic Release Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Test Pressure . . . . . . . . . . . . . . . . . . . . 105-2 Park Brake—Manual Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 105-3 Brake Disk Inspection . . . . . . . . . . . . . . . . 105-4 Annular Brake Piston Inspection . . . . . . . . . 105-6 Brake Piston Packings Leakdown Test . . . . . . . . . . . . . . . . . . . 105-6 Bleed Brakes . . . . . . . . . . . . . . . . . . . . . 105-7 Group 110—Operational Checks Operational Checks Axle Vertical Movement . . . . . . . . . . . . . 110-1 Planetary Carrier Backlash . . . . . . . . . . . 110-2 Ring Gear and Pinion Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . 110-2 Group 115—Differential and Axle Assembly Tests Differential Housing Tests Air Test Differential Lock System . . . . . . . 115-1 Oil Test Differential Lock System . . . . . . . 115-2 Differential Lock Sealing Ring Test . . . . . . 115-3 Air Test Axle Assembly . . . . . . . . . . . . . 115-4 No-Spin Differential Installation Test . . . . . . . . . . . . . . . . . . 115-5 Operation Test . . . . . . . . . . . . . . . . . . . 115-5 Differential Test . . . . . . . . . . . . . . . . . . 115-6 Differential Lock Function Test . . . . . . . . . . 115-7 Group 120—Theory of Operation Axle Oscillation . . . . . . . . . . . . . . . . . . . . 120-1 Axle Disconnect . . . . . . . . . . . . . . . . . . . . 120-2 Inboard Planetary Axle . . . . . . . . . . . . . . . 120-3 Differential . . . . . . . . . . . . . . . . . . . . . . . 120-4 Standard Differential . . . . . . . . . . . . . . . . . 120-5 Dif-Lok Differential . . . . . . . . . . . . . . . . . . 120-6 No-Spin Differential . . . . . . . . . . . . . . . . . 120-7 Page Capture System . . . . . . . . . . . . . . . . . . . . 120-8 Air Boost System . . . . . . . . . . . . . . . . . . . 120-9 Pressurized Differential Case . . . . . . . . . . . 120-9 Service Brake—Single Disk . . . . . . . . . . . 120-10 Service Brake—Multiple Disk . . . . . . . . . . 120-11 Park Brake—Manual . . . . . . . . . . . . . . . . 120-12 Park Brake—Spring Applied/Hydraulic Release . . . . . . . . . . . . . . . . . . . . . . . 120-14 Dry Drum Brake . . . . . . . . . . . . . . . . . . 120-15 Group 499—Dealer Fabricated Tools DF1055 Yoke Holding Tool . . . . . . . . . . . . . . . . . 499-1 DF1057 Axle Adjusting Tool . . . . . . . . . . . . . . . . 499-2 DFRW7 Differential Lifting Tool . . . . . . . . . . . . . . 499-3 DFRW102 Pinion Shaft Tool . . . . . . . . . . . . . . . . . 499-4 Index Contents CTM43 (18FEB98) iv 1200, 1400, 1600 TeamMate II Axles 180298 PN=329 40 41 42 43 45 100 105 110 115 120 499 INDX

John Deere TeamMateII 1200/1400/1600 Series Inboard Planetary Axles Workshop Service Repair Manual

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