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
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