Service Manual - JCB 8250 Fastrac Transmision

Section F
Transmission
Service Manual - JCB 8250 Fastrac
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Optional Equipment
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section S - Suspension
Section T - Engine
Publication No.
9803/8070-1
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section F - 1Transmission
Notes:
F-0 9803/8070-1 F-0

Contents Page No.

Technical Data
Continuously Variable Transmission (CVT) ..............................................F - 1
Pressure Settings ................................................................................F - 1
Axles .........................................................................................................F - 2
Front Axle ............................................................................................F - 2
Rear Axle .............................................................................................F - 2
General Description
Drive Line Layout ......................................................................................F - 3
CVT Description
Main Component Identification .................................................................F - 4
Actuator Unit .............................................................................................F - 6
Hydraulic Circuit .......................................................................................F - 7
Key ......................................................................................................F - 8
Valve Block 1 ............................................................................................F - 9
Valve Block 2 ..........................................................................................F - 11
High Pressure Relief Valve, Forward/Reverse .......................................F - 13
Purge Valve ............................................................................................F - 14
CVT Operation
Operation in Different Modes ..................................................................F - 15
Engine at idle, Machine stopped .......................................................F - 15
99% Hydrostatic - 1% Mechanical .....................................................F - 17
50% Hydrostatic - 50% Mechanical ...................................................F - 18
0% Hydrostatic - 100% Mechanical, Machine Speed 67 km/h, Engine 1500
rev/min ...............................................................................................F - 19
100% Hydrostatic Power Transmission, Medium Speed, Annulus rotates
faster than engine ..............................................................................F - 20
Pressure Testing
CVT ........................................................................................................F - 21
Low Pressures ...................................................................................F - 21
High Pressure ....................................................................................F - 23
Differential Lock and PTO .......................................................................F - 24
Differential Lock .................................................................................F - 24
PTO Speed Pressures .......................................................................F - 25
CVT Valves
Purge Valve ............................................................................................F - 27
Removal and Replacement ...............................................................F - 27
Forward and Reverse High Pressure Relief Valves ...............................F - 28
CVT Cartridge
Removal and Replacement ....................................................................F - 29
Removal ............................................................................................F - 30
Replacement .....................................................................................F - 35
Filling the Transmission Oil ...............................................................F - 44
Clutch Hydraulics
Master Cylinder ......................................................................................F - 45
Dismantling and Assembly ................................................................F - 45
Filling and Bleeding the System .............................................................F - 47
F-i F-i
Contents
Contents Page No.

Front Axle
Removal and Replacement ....................................................................1 - 49
Removal ............................................................................................1 - 50
Replacement .....................................................................................1 - 51
Hub .........................................................................................................1 - 52
Component Key .................................................................................1 - 52
Dismantling ........................................................................................1 - 54
Inspection ..........................................................................................1 - 57
Assembly ...........................................................................................1 - 58
Drive Head ..............................................................................................1 - 66
Removal and Replacement ...............................................................1 - 66
Component Key .................................................................................1 - 68
Dismantling ........................................................................................1 - 70
Inspection ..........................................................................................1 - 72
Assembly ...........................................................................................1 - 74
Rear Axle
Removal and Replacement ....................................................................F - 83
Removal ............................................................................................F - 83
Replacement .....................................................................................F - 84
Hub .........................................................................................................F - 86
Component Key .................................................................................F - 86
Dismantling ........................................................................................F - 88
Inspection ..........................................................................................F - 90
Assembly ...........................................................................................F - 92
Drive Head ..............................................................................................F - 97
Component Key .................................................................................F - 99
Dismantling ......................................................................................F - 101
Inspection ........................................................................................F - 103
Assembly .........................................................................................F - 105
Rear PTO Input Shaft ......................................................................F - 114
Rear PTO Gearbox ...............................................................................F - 115
Component Key ...............................................................................F - 116
Dismantling ......................................................................................F - 117
Inspection ........................................................................................F - 121
Assembly .........................................................................................F - 121
F - ii F - ii
Technical Data
Continuously Variable Transmission (CVT)
Technical Data
Continuously Variable Transmission (CVT)
Type A continuously variable transmission for forward and

reverse travel
Low Range Speed Forward Speeds depend on tyre size

Low Range Speed Reverse Speeds depend on tyre size
High Range Speed Forward Speeds from 0 to 67 km/h (42 mph)

High Range Speed Reverse Speeds depend on tyre size
Pressure Settings
Note: All pressures are at transmission oil temperature of
37-43 deg C
Test Test Point bar lbf/in2

Circuit Pressure - hydrostatic angle servo and range shift P 23-27 334-392
Servo Pump Outlet PU 23.5-27.5 341-399
Supply Pressure to Hydrostatic Loop ES 18-22 261-319
Return Pressure from Hydrostatic Loop AS 11.5-15.5 167-225
Lubrication SM 3-4 44-58
Rear PTO Clutch PTO 18-21 261-305
4WD Valve Pressure 4WD 18-21 261-305
Low Range Solenoid 1 23-27 334-392
High Range Solenoid 11 23-27 334-392
High Pressure Relief Valves (forward and reverse) PH
(New Valves) 535-565 7760-8195
(Used Valves) 520-560 7540-8120
Differential Lock D 18 260
PTO 540 rpm TP3 18 260
PTO 1000 rpm TP4 18 260
F-1 9803/8070-1 F-1

Technical Data
Axles
Axles
Front Axle
Type Crown wheel and pinion primary reduction with epicyclic

hub reduction
Mounting 4 leading link control arms and Panhard rod
Differential Soft engaged differential lock with electro-hydraulic
control
Dry Weight 902 kg 1989 lb
Rear Axle
Type Crown wheel and pinion primary reduction with epicyclic

hub reduction
Mounting 2 trailing link control arms and 'V' link
Differential Soft engaged differential lock with electro-hydraulic
control
Dry Weight 1460 kg 3219 lb
F-2 9803/8070-1 F-2

General Description
Drive Line Layout
General Description
Drive Line Layout
Fig 1.
The CVT transmission is driven from the engine via a
Key
damper and drive shaft. The transmission is also resiliently
1 Engine mounted in the chassis.
2 CVT Input shaft
The drive shaft output from the transmission to the rear
3 CVT Transmission
axle incorporates the park brake disc.
4 Rear PTO shaft
5 Rear axle including PTO The PTO output from the gearbox drives the input to the
PTO box incorporated in the rear axle.
6 Rear drive shaft
7 Hydraulic pump assembly The fully suspended rear axle incorporates a 2 speed PTO
8 Front drive shaft box. Axle lubrication, soft engage differential lock .
9 Front steer axle The front wheel drive is via a soft engage clutch in the
10 Front PTO and input shaft from engine transmission driving the front fully suspended steer axle.
crankshaft
The front PTO box is driven directly from the front
The Fastrac drive line comprises the following crankshaft coupling on the engine
components:
A Turbo-charged 6 cylinder engine which is resiliently

mounted in the chassis with 4 rubber mounts.
F-3 9803/8070-1 F-3

CVT Description
Main Component Identification
CVT Description
INE
ENG F
A
D
B
C
G
J
P
L
N M
Fig 2.
F-4 9803/8070-1 F-4

CVT Description
Key
A Input from engine
B Output to front axle
C Oil Filter
D Mounting shaft - bottom
F Mounting shaft - top
G Top cover
H Actuator unit
J Valve block 1
K Valve block 2
L Speed sensor
M Oil Strainer
N Output to rear axle
P Output to rear PTO
Q High/low range sensor
The CVT is a continuously variable transmission for

forward and reverse travel with integrated synchronised
range shifting. Power transmission can be hydrostatic or
mechanical or hydrostatic and mechanical.
The CVT cartridge is flexibly mounted in the transmission

housing by mounting shafts D and F. The transmission
housing is also the oil reservoir for the hydrostatic drive.
Low Range
For speeds from 0 - 32 km/h (20 mph). Intended for
heavy traction work at low travel speeds i.e. less than 12
km/h (7.5 mph).
High Range
For speeds from 0 - 67 km/h (42 mph). Intended for use
on roads (transporting applications).
Note: In circumstances where the engine will run but it is

not possible to select the required mode due to selector
failure, the transmission can be put into a limp home mode
to enable the machine to be moved to a location suitable
for repairs to be made. In limp home mode the actuator
shaft is operated manually from the cab (see Operator
Handbook) and the transmission is automatically limited to
approximately 30km/h.
F-5 9803/8070-1 F-5

CVT Description
Actuator Unit
Actuator Unit
The actuator unit controls the actuator shaft, changing the the analogue position sensor (potentiometer) on the
transmission ratio in the CVT transmission. accelerator.
The actuator unit comprises: When control set point transmission ratio has been
reached, the machine is put under load and the
1 Drive for limp home mode (if required to move the engine speed drops. The automatic maximum output
machine in case of failure of the electronic control control only ever changes the transmission ratio
system). towards slow. The automatic maximum output control
is engaged if the reduction in engine speed of over
2 The clutch for the drive. 180 rev/min.+ set value
3 Incremental encoder which is a position sensor with

Example:
digital resolution emitting 8000 pulses per revolution.
Engine speed according to accelerator
4 Planetary gear i = 192:1 (electric motor to the actuator pedal position 2000 rev/min
shaft). Setting for automatic maximum output
control 10% 200 rev/min
5 Electric motor 12V DC 0.4 to 7 amps (actuator unit no
load sped of 4500 rev/min).
Calculation:
6 Slip clutch 2.5 to 3.5 Nm. (4 to 5 Nm at key operated 2000 rev/min
actuator of limp home control).
minus 180 rev/min
Once the ignition is on, the actuator unit locates the minus 200 rev/min
reference point (approximate neutral point between Result 1620 rev/min
forward and reverse travel).
This means that the automatic maximum output
Once the engine has started, the actuator unit locates
control changes the transmission ratio toward slow
the reference point (exact neutral point between
from 1620 rev/min. Theoretically the automatic
forward and reverse travel).
maximum output control changes the transmission
ratio when under load until the travel speed reaches
7 Automatic maximum output control
0.
This restricts the reduction in engine speed or
adaptation to the engine output.
The engine speed is reduced when a load is applied.

The electronics change the transmission ratio
towards slow so that the engine speed is not reduced
too far.
Automatic maximum output control is always

engaged once the engine is started. However, the
reduction in engine speed can be changed from 0 to
30% The default setting is 14%.
Automatic maximum output control functions:
The electronics detect the set point engine speed

from the position of the accelerator pedal by means of
F-6 9803/8070-1 F-6

Hydraulic Circuit
F-7
M18 24 25
6A1 6A4 (AR)
M11 (ZWK)
26 6V1 27 6V4
M10
4Z2
V=0.3 l
p =10 bar
4S1 II o
23 4Z1 p M9 (PH) M22 (PH) M6 (P) PHA M7 (I) M8 (II)
4V5 4V4 p=18 bar

4V6 4V3 4V1 4V2
1
9803/8070-1
21
3Z2
6 1Z4 17
20 3Z1 3A3 22
M 4A1
100 l/min
1V6 p=25bar 18 19
unter Last
lastlos 110 l/min 1Z2 3V1 3V2
ø2% ø2% ø3% ø3%
p=5bar
p =7bar
1Z3 1V1
p=3.5bar 3A1 3A2
28 1V2 ì10 =75 (10Ým abs) 15 16
1V5 p=50bar
p=6.5bar p=6.5bar
9 2V1 12 2V4 p=7bar
ø1%
68l/m
68 n
l/min 2 8 2P1 2V5
p=0- 500bar
13
4 T U 3
23.4 ccm/U
1P2 1S1
1P1
10 14 p=0- 500bar
2V6
CVT Description
p=10bar 14 ccm/U
1V4 2V2 ø1% 2A1 7 2A2
233 ccm/U 233 ccm/U 233 cm/U
1Z1 11 2V3
Hydraulic Circuit
p=0.25bar
%75)
20 m 50
15 m nom.
5
F-7
Fig 3.
Key to be supplied or consumed. The variable
F-8
23 (4Z1) Clutch master cylinder

displacement pump and motors swivel accordingly.
24 (6A1) Rear PTO clutch
Main Components
25 (6A4) 4WD clutch If the clutch pedal, park brake or neutral switch is
Note: The item numbers/letters in brackets are shown 26 (6V1) Solenoid valve, PTO operated, the turbo clutch pressure limiting valve is
in red on the circuit diagram. used to depressurise the high pressure circuit by
27 (6V4) Solenoid valve, 4WD clutch means of two high pressure relief valves.
28 (1Z3) Oil cooler K Valve Block 2 ( T F-11)
1 Valve block 1 (items in purple box) Operation of the turbo clutch is controlled by the turbo
K Valve Block 1 ( T F-9) The system uses different pressures: clutch pressure limiting valve. K Valve Block
2 Valve block 2 (items in blue box) K Valve 1 ( T F-9)
Block 2 ( T F-11) 1 System pressure for CVT transmission control
3 (1P1) Servo pump unit approximately. 25 bar (360 lbf/in2) and
enhanced pressure approximately. 18 bar (260
4 Lubrication pump K Valve Block lbf/in2) for rear PTO clutch and differential locks.
(1P2) 2 ( T F-11)
5 Suction filter 2 High pressure in CVT transmission. Max.
6 (1Z4) Transmission lubrication pressure-measuring point approximately. 500
bar (7250 lbf/in2).
7 (2A1 Hydraulic motors
&
9803/8070-1
Cooled transmission oil is supplied to the high

2A2) pressure circuit by two non-return valves alternately.
8 (2P1) Hydraulic pump
The high pressure circuit incorporates a variable
9 (2V1) Charge valve, forwards
displacement charge pump (2P1) and two variable
10 (2V2) Charge valve, reverse displacement motors (2A1/2A2), two non-return
11 (2V3) High pressure relief valve - forwards valves, two servo assisted high pressure relief valves
(2V3/2V4). Hot transmission oil is discharged from the
12 (2V4) High pressure relief valve - reverse
high pressure circuit via the purge valve (2V5).
13 (2V5) Purge valve
14 (2V6) Shuttle valve The circuit also includes a turbo clutch pressure
limiting valve (4V4), a clutch pressure limiting valve
15 (3A1) Pump control cylinder (4V5) and a test connection.K Valve Block
16 (3A2) Motor control cylinder 2 ( T F-11)
17 (3A3) Emergency speed limiter
The regulator cylinders of the variable-displacement
CVT Description
18 (3V1) Pump control valve pump and variable-displacement motors are actuated
19 (3V2) Motor control valve by two 4/3-way valves. The 4/3-way valves are
Hydraulic Circuit
activated by the actuator shaft.
20 (3Z1) Control shaft
21 (3Z2) Transmission control actuator The actuator shaft is rotated as required by the
22 (4A1) Range selector cylinder actuator unit, thereby setting the correct quantity of oil
F-8
CVT Description
Valve Block 1
Valve Block 1
Fig 4.
Note: The item numbers/letters in red are shown in

brackets in the component key.
F-9 9803/8070-1 F-9

CVT Description
Valve Block 1
Component Key
1 (4S1) Main circuit pressure sensor (high
pressure)
2 (4V1) Low range solenoid
3 (4V2) High range solenoid
4 (4V3) Solenoid valve, speed limiter
5 (4V4) Turbo clutch pressure limiting valve
6 (4V5) Clutch pressure limiting valve
7 (4V6) Pressure reducer valve (proportional
valve), pressure reduction to 18 bar, for
rear PTO and 4WD clutches
8 (4Z2) Accumulator
P Test point, Operating pressure,
transmission
M7 (I) Test point, low range solenoid pressure
M8 (II) Test point, high range solenoid pressure
M9 (PH) Test point, High Pressure
PHA Test point, Operating pressure, rear PTO
and 4WD clutches
T Test point, Leak flow clutch valve/turbo-
clutch valve
Note: Some pressure test points are remotely mounted on

a panel at the rear of the cab. K CVT ( T F-21)
F-10 9803/8070-1 F-10

CVT Description
Valve Block 2
Valve Block 2
10
12 5
11
4
6 7
1
2 3
8
12
10
7
5
6
12
Fig 5.
Note: The item numbers/letters in red are shown in

brackets in the component key.
F-11 9803/8070-1 F-11

CVT Description
Valve Block 2
Component Key
1 (1P1) Servo pump
2 (1P2) Lubrication pump
3 (1S1) Oil temperature switch
4 (1S2) Filter restriction switch
5 (1V1) Cooler bypass valve (3.5 bar)
6 (1V2) Pressure limiting valve, feed line (6.5 bar)
7 (1V3) Pressure limiting valve, supply line (6.5 bar)
8 (1V4) Lubrication pressure limiting valve
9 (1V5) Servo-pump pressure limiting valve (50 bar)
10 (1V6) Servo circuit pressure limiting valve (25 bar)
11 (1Z2) Pressure filter with by-pass
12 (1Z3) Oil cooler
M1 (KV) Test point, Cooler supply Flow
M2 (SM) Test point, Lubrication Pressure
M3 (AS) Test point, Return from hydrostatic loop
M4 (ES) Test point, Supply to hydrostatic loop
M5 (PU) Test point, servo pump outlet pressure
Note: Some pressure test points are remotely mounted on

a panel at the rear of the cab. K CVT ( T F-21)
The transmission oil temperature is monitored by the

temperature sensor (1S1). Oil flow through the oil cooler
(1Z3) depends on the temperature. This means that if the
transmission oil is cold, little oil flows through the oil cooler,
while most flows via the bypass valve which opens when
the pressure differential exceeds approximately. 3.5 bar
(50 lbf/in2).
The servo-pump (1P1) generates the system pressure for

the CVT control valves and the enhanced control valves.
The system pressure of approximately. 25 bar (360 lbf/in2)
is restricted by the pressure-relief valve with its throttling
port.
Contamination of the pressure filter is monitored by a

pressure operated switch (1S2) as a function of the
transmission oil temperature. If the transmission oil
temperature is below 50 deg C, filter contamination is not
monitored.
F-12 9803/8070-1 F-12

CVT Description
High Pressure Relief Valve, Forward/Reverse
High Pressure Relief Valve, Forward/Reverse
1 The pressure is equal in both chambers if the clutch/

turbo clutch valve is closed. the spring holds the PH (4V4/4V5)
position closed.
ES
2 If the clutch or the turbo clutch valve is open, the
pressure drop via the diaphragm (x piston surface
area) is greater than the spring load. The piston PH
moves to the right and connects PH with ES.
3 The pressure is relieved by the clutch and the turbo

clutch valves.
2V4
ø1%
p=0- 500bar
2V6 p=0- 500bar
ø1%
2V3
ES
PH
A B A C
F-13 9803/8070-1 F-13

CVT Description
Purge Valve
Purge Valve
pA
A T B
XA pB
XB
XA A T B XB
p=7bar
Fig 8.
2V5
Tractive mode
pA > pB, delta p > 7 bar
Fig 6.
Piston is pushed upwards via control bore XA.
Pressure at A, B max 500 bar
Channel B is linked to T. Hot oil can flow from low
Pressure at T max 50 bar pressure side B via T to discharge connection and
Opening pressure: delta p = 7 bar between A and B. to the oil cooler.
pA pB pB
pA
XA A T B XB XA A T B XB
Fig 7.
Fig 9.
Transmission in Neutral
Pushing Mode
pA = pB, delta p < 7 bar
pA < pB, delta p > 7 bar
The piston is held in mid position by spring force
Piston is pushed downwards via control bore XB.
Both channels (A, B) are closed.
Channel A is linked to T. Hot oil can flow from low
pressure side A via T to discharge connection and
to the oil cooler.
F-14 9803/8070-1 F-14

CVT Operation
Operation in Different Modes
CVT Operation
Engine at idle, Machine stopped
540 1000
1 11
Fig 10.
F-15 9803/8070-1 F-15

CVT Operation
Key
1 Planetary gears
2 Hydraulic pump
3 Connecting shaft
4 Hydraulic Motors
5 Range shift
Planetary gear/power splitting
A Planet carrier (drive from engine)

B Annulus (Drive to pump)
C Planet wheel
D Sun wheel (Drive to accumulator shaft)
F-16 9803/8070-1 F-16

CVT Operation
99% Hydrostatic - 1% Mechanical
540 1000
1 11
Fig 11.
F-17 9803/8070-1 F-17

CVT Operation
50% Hydrostatic - 50% Mechanical
540 1000
1 11
Fig 12.
F-18 9803/8070-1 F-18

CVT Operation
0% Hydrostatic - 100% Mechanical, Machine Speed 67 km/h, Engine 1500 rev/min
540 1000
1 11
Fig 13.
F-19 9803/8070-1 F-19

CVT Operation
100% Hydrostatic Power Transmission, Medium Speed, Annulus rotates faster than
engine
540 1000
1 11
Fig 14.
F-20 9803/8070-1 F-20

Pressure Testing
CVT
4WD PTO
ES P
AS SM
C070620
Fig 15.
Low Pressures Table 1.

Test Test Point
Most pressure test points are located on a panel at the Circuit Pressure - hydrostatic P
back of the machine. K Fig 15. ( T F-21) angle servo and range shift K Fig 15. ( T F-21)
Servo Pump Outlet Pressure PU on Valve Block 2
Do all low pressure tests at a transmission oil temperature
K Fig 16. ( T F-22)
of 37-43 deg C and an engine speed of 1200 rpm.
Supply Pressure to Hydrostatic ES
See Technical Data for specified pressures. K Pressure Loop K Fig 15. ( T F-21)
Settings ( T F-1) Return Pressure from Hydrostatic AS
Loop K Fig 15. ( T F-21)
Connect a pressure gauge to the relevant test point.
Lubrication Pressure SM
Test the following pressures with the transmission in K Fig 15. ( T F-21)
neutral. K Table 1. ( T F-21) 4WD Clutch Pressure 4WD
K Fig 15. ( T F-21)
Rear PTO Clutch Pressure PTO
K Fig 15. ( T F-21)
F-21 9803/8070-1 F-21

Pressure Testing
CVT
I II
PU
Fig 16.
Test the following pressures, as the appropriate range

range is selected. K Table 2. ( T F-22)
Note: The pressure reading will be shown for only half a

second.
See Technical Data for specified pressures. K Pressure

Settings ( T F-1)
Table 2.
Test Test Point
Low Range Solenoid Pressure l on Valve Block 1
K Fig 16. ( T F-22)
High Range Solenoid Pressure l l on Valve Block 1
K Fig 16. ( T F-22)
F-22 9803/8070-1 F-22

Pressure Testing
CVT
High Pressure
PH
C070620-B1
Fig 17.
!MCAUTION 5 Repeat the above procedure but select reverse drive

instead of forwards.
Do not select forward or reverse drive with brakes
applied for any longer than 5 seconds as there is a risk Note: Do not depress clutch pedal during the test.
of overheating the transmission oil.
13-2-4-17
1 Ensure transmission oil temperature is 37-43 deg C.
2 Apply park brake. Connect 0-600 bar (0-8500 lbf/in2)

pressure gauge to test point PH.
Important: Make sure the correct 0-600 bar (0-8500 lbf/

in2) pressure gauge is used as lower capacity gauges
would be damaged by the high pressure.
3 Select 4WD, select high range, select powershift

range, gear 1.
4 Apply foot brakes, select forward travel, increase

engine speed to 1600 rpm and check gauge reading.
The tractor should not move. See Technical Data for
specified pressures. K Pressure Settings ( T F-1)
F-23 9803/8070-1 F-23

Pressure Testing
Differential Lock and PTO
Differential Lock
C070620-B2
Fig 18.
Connect a 0-40 bar (0-600 lbf/in2) gauge to test point D.
Run the engine at 1200 rpm and select differential lock.
Gradually increase the engine speed to prevent the

possibility of damage to the gauge if the pressure was set
too high. The gauge reading at maximum engine speed
will indicate the setting of the pressure maintenance valve
CT7. K Fig 19. ( T F-25)
Note: This valve also controls the PTO Speed Pressures

K PTO Speed Pressures ( T F-25)
For specified pressures K Pressure Settings ( T F-1)
If required, adjust at the pressure maintenance valve CT7.

K Fig 19. ( T F-25)
Note: If this is the first time the valve has been adjusted,
the adjusting screw will be covered by a plastic cap which
should be removed and discarded.
F-24 9803/8070-1 F-24

Pressure Testing
PTO Speed Pressures
CT7
TP3
TP4
C070550
Fig 19.
Connect a 0-40 bar (0-600 lbf/in2) gauge to the relevant Run the engine at 1200 rpm and select the relevant PTO
test point. speed.
Gradually increase the engine speed to prevent the

PTO 540 rpm TP3
possibility of damage to the gauge if the pressure was set
PTO 1000 rpm TP4 too high. The gauge reading at maximum engine speed
will indicate the setting of the pressure maintenance valve
CT7. K Fig 19. ( T F-25)
F-25 9803/8070-1 F-25

Pressure Testing
Note: This valve also controls the differential lock.
Pressure K Differential Lock ( T F-24)
For specified pressures K Pressure Settings ( T F-1)
If required, adjust at the pressure maintenance valve CT7.

K Fig 19. ( T F-25)
Note: If this is the first time the valve has been adjusted,
the adjusting screw will be covered by a plastic cap which
should be removed and discarded.
F-26 9803/8070-1 F-26

CVT Valves
Purge Valve
Removal and Replacement

1 Drain the transmission oil, unscrew the screw plug A
on the bottom of the transmission housing.
2 Remove the purge valve using a socket wrench.
Only renew the Ò'-rings if there is damage. Check

A
the position of the support rings. Tighten the purge
valve to 200 - 210 Nm (150 - 155 lbf ft).
3 Fill the transmission with oil using the pressurised oil

filling procedure. See Filling the Transmission Oil.
C
B
Fig 20.
F-27 9803/8070-1 F-27

CVT Valves
Forward and Reverse High Pressure Relief Valves
Forward and Reverse High Pressure Relief Valves

1 Drain the transmission oil, unscrew the two screw
plugs B and C on the bottom of the transmission
housing.
2 Remove the high pressure relief valves using a A

socket wrench.
B High pressure relief valve - Reverse

C High pressure relief valve - Forward
3 The high pressure relief valve is a pilot controlled

pressure relief valve.
Pressure Setting C
New: 500 + 20 bar (7250 + 290 lbf/in )
2 B
Used: 460 - 500 bar (6670 - 7250 lbf/in2)
Only renew the Ò'-rings if there is damage. Check Fig 21.

the position of the support rings. Tighten the high -
pressure relief valve to 250 - 270 Nm (185 - 200 lbf ft).
4 Fill the transmission with oil using the pressurised oil

filling procedure. See Filling the Transmission Oil.
F-28 9803/8070-1 F-28

CVT Cartridge
CVT Cartridge
14
5
3
15
Fig 22.
Key - upper view Key - upper view
1 18 bar for control line adjustment 14 Mounting shaft - bottom
2 Mechanical speed limiting 15 Mounting shaft - top
3 Range change control 1
4 Range change control 2
5 High pressure to clutch and
turbo-clutch function
6 Pressure supply to the enhanced
shift system
8 Clamps - top
9 CVT Cartridge
F-29 9803/8070-1 F-29

CVT Cartridge
13
10
11
12
Fig 23.
7 Close the pressure hose of the clutch actuation
Key - lower view
system to prevent it from draining.
10 Access to clamp nuts
11 HP valve - forwards 8 Unscrew the pressure pipe and bleed line of clutch
actuation system from the valve unit 1.
12 HP valve - reverse
13 Access to flushing valves and 9 Loosen the fastening screws. Screw two M8 stud
transmission oil drain bolts into the gearbox housing. remove the complete
valve unit 1.
Removal
10 Remove the bolts from gearbox housing cover.
1 Drain the transmission oil.
11 Fit eye bolt to the cover and hoist, taking appropriate
2 Disconnect and unscrew the range control cable. safety precaution
3 Unscrew the range control bracket.
4 Unscrew the range control support.
5 Remove the actuator unit from the gearbox and

disconnect the electrical lead.
6 Mark the electrical leads to the solenoid valves and

disconnect.
F-30 9803/8070-1 F-30

CVT Cartridge
12 Unclip all circlips and discard, always use new circlips

Press hose assemblies inwards.
13 Disconnect the electrical lead and remove the sensor.
14 Unscrew the hydraulic lines from the valve housing.
Disconnect the electrical lead.
15 Remove the valve 2 housing.
Fig 24.
16 Unclip the three circlips and remove the valve plate.
Fig 25.
17 Remove the hydraulic hose (pressure supply) to the
enhanced shift system.
Fig 26.
F-31 9803/8070-1 F-31

CVT Cartridge
18 Unclip the drive shaft circlip, push the drive to the rear.
Fig 27.
19 Unscrew the three M8 hexagon screws from the
planetary gear, push the drive shaft to the rear.
Fig 28.
20 Unclip the circlip from the pinion shaft. Slide the circlip,
washer and the coupling sleeve onto the pinion shaft in
the direction of the arrow.
Fig 29.
F-32 9803/8070-1 F-32

CVT Cartridge
21 Pivot the hydraulic motors inwards using a tyre lever.
22 Unscrew the two M20 hex nuts on each side of the
housing.
Fig 30.
23 Loosen the two M12 clamping screws at the top.
Unscrew two drain plugs on the underside of the
gearbox. Collect any draining oil. Loosen the two M12
clamping screws.
Fig 31.
24 Attach a hoisting yoke to the CVT cartridge. Take up
the tension. Take appropriate safety precautions
Fig 32.
F-33 9803/8070-1 F-33

CVT Cartridge
25 Attach a slide hammer puller with a modified M20 nut
adaptor. Withdraw the mounting shafts.
Note: The weight of the CVT cartridge is approximately 169

kg (373 lb).
Fig 33.
!MDANGER
Do not stand underneath a raised load. Stand clear and
to one side until the load has been safely lowered. Make
sure that the area is clear of other people before
lowering the load. If you do not follow these
precautions you or others could be killed or seriously
injured.
2-3-5-4
26 Raise the CVT cartridge carefully out of the gearbox

housing using the hoist.
Fig 34.
F-34 9803/8070-1 F-34

CVT Cartridge
Replacement
1 Attach a hoist to the CVT cartridge taking appropriate

safety precautions. Make sure the shift range change
control is set to Neutral (centre position).
Fig 35.
2 Clean the seal surfaces on the transmission housing to
remove oil and seal residues. Move the selector finger
of the range control in transmission housing to Neutral
(mid position).
Fig 36.
3 Fit the circlip onto the collar of the pinion shaft. Slide
the bushing onto the pinion shaft up to the stop. Locate
the flange on the connection shaft (PTO drive) and
insert the connection shaft.
Fig 37.
F-35 9803/8070-1 F-35

CVT Cartridge
4 Insert the CVT cartridge into the gearbox housing.
Ensure clearance for all components. Insert the two
shafts into the bores of the gearbox housing and the
CVT cartridge.
Fig 38.
5 Check the flexible bushes for wear, if necessary fit new
bushes. Insert the four bushes into the bores as far as
the stop.
Fig 39.
6 Locate the ring - with the groove pointing to the flexible
bush. Fit the M20 lock nut. Fit the other three nuts in
the same manner.
Fig 40.
F-36 9803/8070-1 F-36

CVT Cartridge
7 Tighten all four M20 nuts to 250 Nm (184 lbf ft).
Counterhold the nuts when tightening. Remove the
lifting hoist and the M12 eye bolt.
Fig 41.
8 Turn one planet wheel of the planetary gear of the
power splitting system upwards. Align the CVT
cartridge using a feeler gauge. Example: it must be
possible to fit a 0.6 mm (0.02 in) between the annulus
and the transmission housing on each side.
Fig 42.
9 Tighten all four clamp screws to 86 Nm (63 lbf ft).
Replace the seals on the two screw plugs in the
bottom of the transmission housing and tighten.
Operate the range change control (check at the shift
finger).
Fig 43.
F-37 9803/8070-1 F-37

CVT Cartridge
10 Turn the CVT cartridge until one tooth of the toothed
washer is in the centre of the sensor aperture.
Fig 44.
11 Measure the distance to the face of the tooth. Set to a
measurement of 64.25 mm (2.530 in).
CL
64.25
110.5
115
234.4 - 234.8
Fig 45.
12 Coat the seal surface of the Hall-effect sensor with
sealant and insert into the bore of the transmission
housing. Tighten the fastening screws to 25 Nm (18 lbf
ft). Connect the electric cable.
Note: If the Hall-effect sensors are reused, stick two

cardboard strips each 0.9mm (0.030 in) thick into the slit in
the Hall effect sensor on the left and right (for centring when
fitting).
Fig 46.
F-38 9803/8070-1 F-38

CVT Cartridge
13 Pivot the hydraulic motors outwards as far as the stop
(45°).
Fig 47.
14 Slide the sleeve onto the pinion shaft until the groove
for the circlip is uncovered. Fit the circlip into the
groove.
Note: If the sleeve does not engage, jack up one of the front
wheels and rotate until the sleeve engages.
Fig 48.
15 Mount the flange on the planetary gear of the power
splitting system. tighten the three M8 hexagon screws
to 25 Nm (18 lbf ft).
Fig 49.
F-39 9803/8070-1 F-39

CVT Cartridge
16 Insert the hydraulic hoses into the bores of the
transmission housing behind valve block 2. Secure the
inserted hoses in place with circlips (opening facing
down).
a Short blue hose (discharge)
b Long blue hose (feed)
c Black hose (lubrication)
Fig 50.
17 Top front of the transmission housing: Fit the circlip into
the shaft groove. Slide the shaft forward. Insert the
washer.
Engage the circlip in the groove on the spur gear.
Fig 51.
18 Fit the hydraulic hose (pressure supply to enhanced
shift system).
Fig 52.
F-40 9803/8070-1 F-40

CVT Cartridge
19 Insert the pressure hoses into the bores behind the
valve block.
a Pressure supply hydraulic hose (enhanced
pressure)
b Low Range control
c Mechanical speed governor
d High Range control
e Control valves (adjustment)
f High pressure to clutch and turbo-clutch operation
(steel line)
Secure the pressure hoses using circlips.

Fig 53.
20 Screw two M8 stud bolts into the transmission housing.
Fit a new gasket, stick new o-rings into the valve unit 1
using a little grease.
Fig 54.
21 Screw two M8 stud bolts into the transmission housing
at valve block 2. Fit a new gasket, stick new o-rings
into the valve unit 2 using a little grease. Install valve
block 2 and secure with fastening screws tightened to
25 Nm (18 lbf ft). Connect cable coupler.
22 Fit new o-rings to the pressure filter with a little grease,
secure to the transmission housing using screws
tightened to 25 Nm (18 lbf ft).
Fig 55.
F-41 9803/8070-1 F-41

CVT Cartridge
23 Coat the new shaft seal with 1:1 spirit/water mixture
and insert as far as the stop. Fill sealing lips 2/3 full of
grease. Insert actuator shaft.
Fig 56.
24 Mate the depression in the actuator shaft with the
threaded bore. Coat the thread of the hexagon bolt
with synthetic bonding agent and tighten to 25 Nm (18
lbf ft).
Fig 57.
25 Locate the driver plate with the two raised sections
facing the actuator unit.
26 Mount the pre-assembled actuator unit onto the
transmission housing. Tighten the M8 socket head cap
screws to 25 Nm (18 lbf ft). Connect the electric cable.
F-42 9803/8070-1 F-42

CVT Cartridge
27 Unscrew the drain plug PU. Connect the external oil
filling unit and fill with specified oil. K Filling the
Transmission Oil ( T F-44)
Note: During filling pivot hydraulic motors and pump by

turning the shaft. Check that there are no leaks visible from
the hydraulic connections.
28 Coat the transmission housing with sealant and

replace the cover. Torque tighten the M12 hex screws
to 86 Nm (63 lbf ft).
Fig 58.
F-43 9803/8070-1 F-43

CVT Cartridge
Filling the Transmission Oil

1 During normal maintenance, e.g. transmission oil
change and/ or filter change, fill with transmission oil
at left rear. See Changing the Transmission Oil and
Strainer, Section 3.
The external oil filling unit must be used if:
a the transmission unit is replaced or
b the high pressure unit is empty, e.g. after removal

of the high pressure valves or the purge valve.
2 Unscrew the drain plug marked PU and connect the

external oil filling unit. Make sure you use the correct
oil type and volume. See Fluids, Lubricants and
Capacities, Section 3.
Note: At least 10 Litres (2.2 UK gal, 2.6 US gal) must be

added via the connection PU.
3 External oil filling unit with superfine filter.
If there is no oil in the high pressure circuit, the

transmission must be filtered via an external hydraulic
oil filling unit.
The external oil filling unit prevents the hydraulic

pump and the hydraulic motor from running dry.
Note: During filling pivot hydraulic motors and pump by

turning the shaft. Check that there are no leaks visible from
the hydraulic connections.
Item Description
1 Suction line from reservoir.
2 Vacuum meter.
3 Pump.
4 Electric drive motor 230 VAC
5 Superfine pressure filter with filter monitor
6 Pressure hose to port PU.
7 Pressure hose to oil cleaner service hydraulics
(does not operate when external oil filling unit is
used).
F-44 9803/8070-1 F-44

Clutch Hydraulics
Master Cylinder
Dismantling and Assembly
Fig 59.
Dismantling 2 While preventing the piston from flying out due to the
force of the internal spring, remove retaining ring C
!MWARNING and washer D.
Always wear safety glasses when dismantling 3 Remove piston assembly E and spring F.
assemblies containing components under pressure
from springs. This will protect against eye injury from 4 If renewal is required, remove insert plug G.
components accidentally flying out.
GEN-6-2 Before assembly, clean all components carefully and
lubricate with the specified clutch system fluid, see Fluids,
1 Disengage boot A from the cylinder and pull out the Capacities and Lubricants, Section 3. Do not let any
push rod B. other fluid come into contact with the components of the
master cylinder.
Note: Avoid using sharp edged tools that could damage
the boot.
F-45 9803/8070-1 F-45

Clutch Hydraulics
Master Cylinder
!MCAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves.
Cover cuts or grazes.
2-3-5-1_2
Assembly
1 Fit new insert plug G.
2 Fit spring F onto a new piston assembly E.
3 Push piston and spring into the bore and hold in

position while fitting washer D and retaining ring C.
4 Fit push rod B and boot A.
F-46 9803/8070-1 F-46

Clutch Hydraulics
Filling and Bleeding the System
C070650
Fig 60.
Important: Filling and bleeding cannot be done by the bleeding kit. Shut off the pressure supply as soon as
conventional method. The system must be filled and bled reservoir A is full of fluid.
via the remotely-mounted bleed screw B using a pressure
bleeding kit as detailed below. 5 Refit the cap to reservoir A. Tighten the bleed screw.
Operate the clutch and check the clutch hydraulic
1 Remove the cap from fluid reservoir A. Do not fill this system for leaks.
reservoir with fluid.
6 Disconnect the spare reservoir C and pressure
2 Connect a spare fluid reservoir C to bleed screw B, bleeding kit.
using a suitable bleeding tube D.
3 Fill the spare reservoir C with the specified fluid (see

Fluids, Lubricants and Capacities, Section 3) and
connect a commercially available pressure bleeding
kit to the spare reservoir C.
4 Slacken bleed screw B. Watch for fluid rising in

reservoir A and apply pressure via the pressure
F-47 9803/8070-1 F-47

Clutch Hydraulics
C068990-B2
Fig 61.
F-48 9803/8070-1 F-48

Section 1 - 1
Front Axle
B K
J
E
H
F
D
Fig 62.
1-49 9803/8070-1 1-49

Section 1 - 1
Front Axle
Removal around the axle (one each side) and raise it to

take the axle weight.
!MWARNING 5 Remove the road wheels and drain oil from hubs and
Make the machine safe before getting beneath it. Park axle.
the machine on level ground and lower the
attachments. Stop the engine and remove the starter 6 Disconnect the axle mounted speed sensor flying
key. Make sure the park brake is engaged. Disconnect leads B, one at each hub, from their chassis mounted
the battery to prevent the engine being started. Block mating connectors. Tie the cable sheathing to the
all four wheels before getting under the machine. axle for protection during the following procedure.
3-3-1-1
7 Disconnect brake pipes C and seal to prevent entry of
dirt.
!MWARNING
This component is heavy. It must only be removed or !MCAUTION
handled using a suitable lifting method and device.
Do not hammer the cast iron lugs on the axle as this
BF-4-1_1
will cause weakness and may lead to steering failure.
!MWARNING AXL 8-2
8 Disconnect the steering assistor ram from the

Raised Equipment
steering swivel at D, using a suitable ball joint splitter.
Never walk or work under raised equipment unless it
Tie up the ram clear of the axle.
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
9 Disconnect the steering drag link from the steering
drop and injure you if the hydraulic system fails or if
lug on the right side hub E, using a suitable ball joint
the control is operated (even with the engine stopped).
splitter. Tie up the drag link clear of the axle.
13-2-3-7_2
1 Remove the two front fender assemblies. 10 Disconnect the shock absorbers from the axle F.
2 Loosen the front road wheel retaining nuts. 11 Disconnect the 4WD shaft at G.
3 Position a jack under the axle and jack the machine 12 Remove Panhard rod at the axle end H, using a
just far enough to allow clearance under the front of suitable ball joint splitter. Tie up the rod clear of the
the chassis for the axle to pass beneath. Install axle axle.
stands (see Step 4).
13 Lower the jack until springs J are fully extended.
4 Position axle stands (which should be capable of
taking the full weight of the machine) on either side of !MCAUTION
the chassis. Lower the jack until the chassis rests on
the axle stands, but make sure it still supports the Keep your hands clear of the springs until they have
weight of the axle. been released and are no longer under load or you
may trap your fingers.
Two alternatives to steps 3 and 4: SUS-1-4
a Hoist the whole of the front of the machine (if 14 Lever the springs so that they are not jammed on the
suitable equipment is available) and then insert axle spigots.
axle stands as described above. Position a jack
beneath the axle and raise it to take the axle 15 With the axle still supported, disconnect the four
weight. control arms K from the axle (see Front Suspension,
Control Arm, Section S). Tie up the control arms to
b Position axle stands as described above. Use a prevent them hanging on the ground. The axle is now
hoist with a cross beam and two chain links free and can be pulled forwards.
1-50 9803/8070-1 1-50

Section 1 - 1
Front Axle
Replacement
Replacement is the reverse of the removal procedure.
Ensure that the chassis is correctly supported as
described previously. K Removal ( T 1-50)
See the relevant Removal and Replacement pages for

correct fitting procedures and torque settings of the
following:
1 Springs, see Section G
2 Shock absorbers, see Section G
3 Panhard rod, see Section G
4 Control arms, see Section G
5 4WD shaft, see Propshafts, Section F
Bleed the brakes, see Section G
Check front wheel alignment, see Checking and

Adjusting the Front Wheel Alignment in section 3.
On completion, fill the axle with the correct oil, see Fluids,
Lubricants and Capacities, Section 3.
1-51 9803/8070-1 1-51

Section 1 - 1
Front Axle
Hub
Hub
Fig 63.
Component Key 6 Gear Carrier

7 Hub
1 Screw 8 Circlip
2 Cover 9 Sun gear
3 O ring 10 Thrust washer
4 Backing plate 11 Drive shaft
5 Screw 12 Circlip
1-52 9803/8070-1 1-52

Section 1 - 1
Front Axle
Hub
13 Lock plate
14 Ring nut
15 Ring gear
16 Lock ring
17 Ring gear support
18 Outer wheel bearing
20 O ring
21 Bolt
22 Brake disc
23 Spacer
24 Seal
25 Bearing
28 Pole wheel
30 Bolt
31 Sleeve
32 Seal
33 Bearing
37 Stud
38 Cover
39 Bolt
40 Cover
41 Shim
42 Swivel pin
43 Bearing
45 Steering knuckle
46 Seal
48 Bearing
49 Pin
50 Bearing
53 Side Gear
1-53 9803/8070-1 1-53

Section 1 - 1
Front Axle
Hub
Dismantling
DR
LEVEL
AIN
OIL
Fig 64.
1 If not already done, drain the oil from the axle and 9 Remove the ring nut 14 using an accurately fitted tool
hub. A (see Service Tools)
2 Remove the service brake calliper units from the 10 Suitably support the hub 7 and pull out the ring gear
axle.(See Footbrake Callipers, Section G). assembly 15.
3 Remove the six screws 1 and, using the three tapped

holes provided, use screws to pull off the cover 2.
Remove and discard O-ring 3.
4 Pull out the axle shaft backing plate 4 using a puller

screw (M8).
5 Remove the screws 5 and, suitably supporting the

side gear carrier 6, pry the carrier 6 from the wheel
hub 7, using levers in the recesses provided.
6 Remove the circlip 8 retaining the sun gear 9 on the

drive shaft 11 and pull out the sun gear.
7 Remove the thrust washer 10.
8 Pull out the circlip 12 securing the ring nut lock plates
13. Remove the lock plates.
Fig 65.
1-54 9803/8070-1 1-54

Section 1 - 1
Front Axle
Hub
11 Pry off the circlip 16 from the ring gear 15 using a
suitable screwdriver.
12 Disassemble the ring gear support 17 from the ring

gear 15.
13 If the replacement of the outer wheel bearing 18 inner

race is necessary, the bearing may be removed by a
suitable puller or by a remover that can be inserted in
the holes of the ring gear support 17.
Fig 66.
Fig 67.
14 Pull out the complete wheel hub 7. Remove and 17 Pry out the seal 24 from the wheel hub and remove
discard the O-ring 20. the inner race of the inner wheel bearing 25.
15 Remove fourteen bolts 21. 18 Using a suitable press, press out the outer races of
the outer wheel bearing 27 and inner wheel bearing
16 Remove brake disc 22 and spacer 23. 26 from hub 7.
1-55 9803/8070-1 1-55

Section 1 - 1
Front Axle
Hub
19 If the pole wheel 28 is damaged, it can be removed
using a suitable extracting tool.
Fig 68.
20 Remove dust shield guard 29. 27 Support the steering knuckle 45 and remove upper
and lower swivel pins, bearings and seals, items 42,
21 Remove bolts 30 and sleeve 31. 43 and 44.
22 Pry out seal 32 and remove the roller bearing 33 from Note: A threaded extraction hole is provided in the end of
sleeve 31. each swivel pin 42.
23 Remove the drive shaft and universal joint assembly 28 Remove seal 46, circlip 47 and bearing 48.
11.
24 Remove nuts 35 and track rod 36.
25 Remove studs 37 and cover 38.
26 Remove bolts 39 and cover 40 with shims 41. Retain

the shims or note the thickness for re-assembly.
1-56 9803/8070-1 1-56

Section 1 - 1
Front Axle
Hub
49 52 50 51 50
53 54
DR
LEVEL
AIN
OIL
Fig 69.
29 Mark the side gear pins 49 and their seating area on smooth and uniform. Renew all gears showing signs of
the carrier 6 for identification of original position at re- such defects.
assembly.
Check that the shimming surfaces of the gears, the
30 Arrange the carrier 6 on wooden blocks and, using a spacers and the shoulder rings show no signs of snagging
suitable press, push out the pins 49. or seizure.
31 Pick up all the needle rollers 50 and spacers 51. Check the threading and the grooving on the shafts are in
good condition.
Note: It is important to keep matched needle rollers and
thrust washers 52 with corresponding pins 49, because of
predetermined assembly tolerance limits.
32 Remove the side gears 53 and corresponding thrust

washers 54.
Inspection
Thoroughly wash all the metallic parts using a solvent,
biodegradable if possible, and blow them with compressed
air. Pay particular attention to the internal lubrication
channels on the shafts, housings and covers, which must
be spotlessly clean.
Check that the housings and the covers show no

indentations and that the bearing seats are intact, without
scoring or ridging.
Check that the surfaces and the edges of the gear teeth
show no signs of wear or spalling. The contact area must
extend over the whole surface of the teeth and must look
1-57 9803/8070-1 1-57

Section 1 - 1
Front Axle
Hub
Assembly
Note: Before assembly, all oil seals for rotating parts
should be soaked in axle oil for half an hour.
1 Fit roller bearing 48 into the axle housing and secure

with circlip 47. Apply grease between lips of seal 46
and fit flush with end of housing
2 Smear seals 44 with grease and fit using suitable seal

driver.
3 Locate the steering knuckle 45 and fit two swivel pins

42 and bearings 43.
43
48
42 47
44 46
44
45
42
43
Fig 70.
1-58 9803/8070-1 1-58

Section 1 - 1
Front Axle
Hub
37
38
31 33 32
30
29
34
Fig 71.
4 Fit upper cover 38, using JCB Threadlocker and

Sealer on studs 37.
Note: Do not fit the lower cover at this stage as shims need
to be selected when checking bearing pre-load.
5 Insert drive shaft 34, making sure that the inner end
locates in the splines of the differential gear.
6 Fit sleeve 31, use JCB Threadlocker and Sealer

(High Strength) on bolts 30 and tighten to 570-630
Nm (420-465 lbf ft). Fit dust shield guard 29.
1-59 9803/8070-1 1-59

Section 1 - 1
Front Axle
Hub
23
24
7 25
26
20
27
21
22
24
Fig 72.
7 Fit the outer races of the wheel inner and outer

bearings 27 and 26 into the wheel hub 7, ensuring
that they are correctly seated. Position the inner race
of the inner wheel bearing 25 before fitting lip seal 24.
8 Smear JCB Multigasket on the outer rim of seal 24

and fit the seal as shown. Apply grease to the seal
lips.
9 Lubricate and fit a new O-ring 20 and spacer 23.
10 Fit brake disc 22. Tighten bolts 21 to 570-630 Nm

(420-465 lbf ft).
11 Mount the support 17 in the ring gear 15 and secure

with the circlip 16.
Fig 73.
1-60 9803/8070-1 1-60

Section 1 - 1
Front Axle
Hub
Fig 74.
12 Suitably support the wheel hub 7 to prevent damage the wheel bearings by setting the rolling force as
to seal 24 and mount the hub and ring gear follows:
assemblies onto the sleeve 31.
Note: To prevent wrong measurement of rolling force, it is
advisable to seat the bearings properly before
measurement by revolving the wheel hub repeatedly.
Measure the rolling force required to maintain rotation

of the hub using cord wrapped around the wheel
studs and a force meter as shown. Ignore the extra
force needed to start rotation. Check the alignment for
the lock plates 13 and adjust the nut 14 to achieve a
pull load of 167 to 206 N (38 to 46 lbf).
Fig 75.
13 Tighten the ring nut 14 using an accurately fitted tool

(see Service Tools) to reach the correct pre-load for
1-61 9803/8070-1 1-61

Section 1 - 1
Front Axle
Hub
adjust the swivel bearing pre-load as detailed in step
16. Tighten bolts 39 to 120-130 Nm (89-96 lbf ft).
14
13
12
Fig 76.
14 Insert the lock plates 13 and fit the circlip 12.
35
41 36
40
39
Fig 77.
15 If no parts of the steering swivel assembly have been

renewed, fit cover 40 using the original thickness of
shims 41. If new parts have been fitted, check and
1-62 9803/8070-1 1-62

Section 1 - 1
Front Axle
Hub
Example
D.T.I. Reading 0.3 mm
Add pre-load 0.9 mm
Total 1.2 mm
Subtract 1.2 from 1.5 0.3 mm
17 When correct shim is fitted, fit grease nipple in cover

38 and tighten bolts 39 to 120-130Nm (89-96 lbf ft).
35
Fig 78.
16 Check and adjust swivel bearing pre-load as follows:
a Insert a 1.5mm thick shim 41 and fit cover 40. 41 36

Tighten bolts 39 to 120-130 Nm (89-96 lbf ft).
40
b Remove the grease nipple from the upper cover 39
38 and position a dial test indicator (D.T.I.) B as
shown. Zero the D.T.I. Fig 79.
c c)Using a lever, lift the hub and steering knuckle 18 Make sure that the wheel alignment is correct and
assembly as far as possible and note the connect the track rod 36 (see Checking and
D.T.I.reading. Adjusting the Front Wheel Alignment in section
3). Tighten nut 35 to 250 Nm (184 lbf ft). If the split pin
d Add a pre-load of 0.9 to 1.0mm to the D.T.I. holes are not aligned, tighten further until split pin can
reading and subtract the total from 1.5mm. The be inserted.
result is the thickness of shim to be fitted in place
of the existing 1.5mm shim.
1-63 9803/8070-1 1-63

Section 1 - 1
Front Axle
Hub
49 52 50 51 50
53 54
DR
LEVEL
AIN
OIL
Fig 80.
19 Arrange the three side gears 53 in their seats in the

side gear carrier 6.
Note: Two rows of needle rollers of the same selection

class should be used for replacement on each single side
gear pin.
20 Insert the inner thrust washers 54. Smear the pin

lower portion (head end) with grease and position the
first row of needle rollers 50. Fit the spacers 51.
Smear the pin upper portion with grease and position
the second row of needle rollers 50.
21 Position the outer thrust washers 52 on the side gears

and align holes.
22 Insert and force fit pins 49, making sure that the
rollers are not dislodged.
1-64 9803/8070-1 1-64

Section 1 - 1
Front Axle
Hub
DR
LEVEL
AIN
OIL
49
Fig 81.
23 Insert the thrust washer 10.
24 Insert the sun gear 9 and secure with the circlip 8.
25 Mount the side gear carrier assembly 6 onto the hub.

tightening the fixing screws 5 to 67-74 Nm (49-54 lbf
ft).
26 Fit drive shaft backing plate 4.
27 Lubricate and fit O-ring 3.
28 Rotate and align pins 49 to allow mounting of cover

2. Fit cover 2. The cover locks the pins, preventing
them rotating.
29 Smear fixing screws 1 with sealing compound, then

tighten to 33-37 Nm (24-27 lbf ft).
30 Ensure the axle is filled with the correct oil (see

Fluids, Lubricants and Capacities, Section 3)
1-65 9803/8070-1 1-65

Section 1 - 1
Front Axle
Drive Head
Drive Head

Important: The axle must be removed from the machine
first because the position of the engine sump prevents the
drive head being removed with the axle in situ.
K Removal ( T 1-50)
!MWARNING
This component is heavy. It must only be removed or
BF-4-1_1
!MWARNING
Make the machine safe before getting beneath it. Park
attachments. Stop the engine and remove the starter
key. Make sure the park brake is engaged. Disconnect
the battery to prevent the engine being started. Block
all four wheels before getting under the machine.
3-3-1-1
Removal
1 Drain the oil from hubs/axle.
2 Position the axle so that the input shaft is pointing

upwards. Remove the road wheels. Fig 82.
!MCAUTION
Do not hammer the cast iron lugs on the axle as this
will cause weakness and may lead to steering failure.
AXL 8-2
3 Disconnect hydraulic pipes at brake callipers.

Remove the track rod and both sets of top and bottom
trunnions. K Dismantling ( T 1-54)
4 Pull the complete hub and swivel assemblies out of

the axle, complete with drive shafts.
5 Remove bolts 1 and lift out the drive head 2.
6 Remove and discard axle oil seals 3.
1-66 9803/8070-1 1-66

Section 1 - 1
Front Axle
Drive Head
Replacement
Apply JCB Multigasket to the mating faces of drive head

and main axle casing. Apply JCB Threadlocker and Sealer
to bolts 1 and torque tighten to 105-116 Nm (77-86 lbf ft).
Replacement is the reverse of the removal procedure
Before assembly, soak seals 3 in axle oil for half an hour

and then pack JCB HP Grease between the seal lips.
Ensure that the seals are fitted squarely and take care not
to damage them when inserting the drive shafts. Grease
the exposed parts of the trunnion pivots to prevent rusting.
Fig 83.
Refit the hub and drive shaft. K Assembly ( T 1-58)
Refit the axle. K Replacement ( T 1-51)
Refill the axle with the specified oil. (See Fluids,

Lubricants and Capacities, Section 3.)
Check the front wheel alignment. (See Checking and

Adjusting the Front Wheel Alignment in section 3).
Bleed the brakes. (See Section G.)
1-67 9803/8070-1 1-67

Section 1 - 1
Front Axle
Drive Head
Component Key
5
2 4
10 1
9
3
8
6
7
14
11
38 22 28
16
31
33
34
35
37
41
39
46
40
43
42
18 45 30 27 29 24 23 21 20
13
44
12 19
Fig 84.
1 Circlip 8 Thrust sleeve
2 Piston back plate 9 Roller bearing
3 O ring 10 End plate
4 O ring 11 Anti-rotation screw
5 Piston 12 Roll pin
6 O ring 13 Castellated nut
7 Spring 14 Castellated nut
1-68 9803/8070-1 1-68

Section 1 - 1
Front Axle
Drive Head
16 Bearing
18 Split bearing carrier
19 Bearing
20 Nut
21 Drive flange
22 Pinion shaft
23 Oil seal
24 Bearing
27 Pinion bearing depth shim
28 Pinion bearing pre-load shim
29 Spacer
30 Bearing
31 Bolt
33 Differential lock actuating sleeve
34 Counter plate
35 Friction plate
37 Shim
38 Pinion gear
39 Trunnion pin
40 Bevel gear
41 Shim
42 Pinion gear
43 Shim
44 Differential case
45 Bolt
46 Crown wheel
1-69 9803/8070-1 1-69

Section 1 - 1
Front Axle
Drive Head
Dismantling
3 4 1
2
6
A 5
9 10
8
7
14
17 18 16 11
12
13 19 15 B
Fig 85.
!MWARNING 3 Apply compressed air to the oil feed port B to force

out the piston back plate 2 from the differential lock
This component is heavy. It must only be removed or housing. Remove and discard 'O' rings 3 and 4.
BF-4-1_1 4 Remove piston 5. Remove 'O' ring 6 and discard.
1 Remove the drive head from the axle K Removal 5 Remove compression spring 7, thrust sleeve 8, axial
and Replacement ( T 1-66) Secure it in a vice or roller bearing 9 and end plate 10.
suitable jig for dismantling and examination.
6 Remove the anti-rotation screw 11 and roll pin 12
2 Fit tool to retain differential lock assembly. (see from the castellated nuts. Remove castellated nuts 13
Service Tools). Remove circlip 1 from the differential and 14.
lock housing.
7 Lay the drive head on a flat surface positioned with
the split bearing carrier 18 uppermost. The weight of
1-70 9803/8070-1 1-70

Section 1 - 1
Front Axle
Drive Head
the assembly 15 should be sufficient to push the 9 Rotate drivehead back through 90° to the vertical
bearing outer cup 16 off its seat. If not, tap the cup out position and remove the differential assembly 15.
gently, using the weight of the differential assembly. If
the cup cannot be removed using this method, Note: During a differential lock repair or piston
remove as detailed in step 8. replacement, inspect the housing for scores, marks or
damage which could cause a leak. If necessary, polish the
8 Rotate the drivehead through 90° to lie in the position housing with oil-lubricated 800 grade or fine abrasive
shown in the illustration. Undo bolts 17 and remove paper to remove any marks. Alternatively, renew the
the split bearing carrier 18 and bearing outer cup 19. housing.
Insert a three leg bearing puller into the differential
lock housing and remove bearing outer cup 16.
22
30
26
27
29
28
25
24
23
21
20
Fig 86.
10 Remove the pinion nut 20. Discard the nut. 15 Tap out the bearing cup 26 from the opposite bearing
housing and remove the pinion bearing depth shim
11 Remove the drive flange 21. 27.
12 Drive the pinion shaft 22 out of the drive head carrier. 16 Remove the pinion bearing pre-load shim 28, spacer
29 and bearing 30 from the pinion shaft.
13 Prise the shaft seal 23 out of the bore.
14 Remove the taper roller bearing 24 and tap out the

bearing cup 25.
1-71 9803/8070-1 1-71

Section 1 - 1
Front Axle
Drive Head
41 37 36
39 40 38
40
42 41
43
46
44
31
19
40
41
40
41
45 16
32
33
34
35
Fig 87.
17 Remove the bolts 31 and separate the differential lock Inspection

case 32 from the rest of the assembly.
18 Remove actuating sleeve 33. biodegradable if possible, and blow them with compressed
air.
19 Remove 11 counter plates 34 and 10 friction plates 35
from the differential pinion gear 38. Check that the housings show no indentations and that the
bearing seats are intact, without scoring or ridging.
20 Separate the differential case halves 36 and 44.
21 Remove the pinion gears 38 and 42, bevel gears 40, show no signs of wear or spalling. Renew all gears
trunnion pins 39, and thrust washers 41 from the case showing signs of such defects.
halves. Remove the thrust washers 37 and 43 from
both case halves. Check that the shimming surfaces of the bearings and
spacers show no signs of snagging or seizure.
22 Remove bolts 45 and separate differential assembly
from the crown wheel 46. Check the threading and the grooving on the shafts are in
good condition.
1-72 9803/8070-1 1-72

Section 1 - 1
Front Axle
Drive Head
Check the mating faces of crown wheel and differential
case. These must be perfectly smooth or fretting will cause
the bolts to work loose.
Note: The bevel gears are a matched set, as are the two
differential case halves also the crown wheel and pinion.
These must be renewed as sets if any of their components
are damaged or excessively worn. Do not use unmatched
components.
Note: The differential case halves are stamped for

matching purposes. The stamp on the crown wheel case
half can only be seen when the crown wheel is removed.
1-73 9803/8070-1 1-73

Section 1 - 1
Front Axle
Drive Head
Assembly
41 37 36
39 40 38
40
42 41
43
46
44
31
19
40
41
40
41
45 16
32
33
34
35
Fig 88.
To enable fitting of inner races of bearings 16, 19 and 30 over the counter and friction plates and align the bolt
pre-heat to 90-110 deg C in oil or in an oven. Do not use a holes with those of the differential case half 36.
flame. Before assembly, lightly oil all bearings and soak all
seals for rotating parts in axle oil for half an hour. 5 Check free rotation of the gears in the horizontal
position (If held vertically the friction and counter
1 Assemble the trunnion pins 39, bevel gears 38, 40, plates would prevent rotation).
42, and their thrust washers 37, 41 and 43 into the
differential case half 44. 6 Fit crown wheel 46 using new bolts 45 and tighten to
120-133 Nm (89-98 lbf ft). Tighten bolts 31 to 65 Nm
2 Position the differential case half 36 aligning the (41 lbf ft) and check free rotation of the gears in the
match mark letters. horizontal position (see previous step).
3 Fit 11 counter plates 34 and 10 friction plates 35,

starting and finishing with a counter plate. Make sure
the counter plate tabs are aligned.
4 Position the actuating sleeve 33 on top of the last

counter plate. Position the differential lock case 32
1-74 9803/8070-1 1-74

Section 1 - 1
Front Axle
Drive Head
22
30
26
27
29
28
25
24
23
21
20
Fig 89.
7 Fit bearing cup 26 in the drive head housing with the

correct thickness of shims 27 as calculated for pinion
depth setting. K Pinion Depth ( T 1-80)
8 Fit pinion bearing 30 onto pinion 22. Fit pinion into

housing.
9 Fit bearing spacer 29, outer race 25 and a thick

enough pre-load shim 28 (e.g 1.5 mm) to provide end
play in the bearings.
10 Fit bearing inner race 24, drive flange 21 (without oil

seal) and tighten nut 20 to 570-630 Nm (420-465lbf
ft).
11 Check and adjust pinion bearing pre-load as follows:
a Position a dial test indicator (D.T.I.) C as shown.

Zero the D.T.I.
b Lift the pinion as far as possible and note the D.T.I.

reading.
Fig 90.
1-75 9803/8070-1 1-75

Section 1 - 1
Front Axle
Drive Head
c Add a pre-load of 0.05 mm to the D.T.I. reading 13 When pinion bearing pre-load is correct, remove the
and subtract the total from the existing shim drive flange and fit seal 23 to the dimension shown at
thickness (e.g 1.5 mm). The result is the thickness D. Apply grease to the inner lips of the seal.
of shim to be fitted in place of the existing 1.5mm
shim. 14 Fit drive flange and tighten nut 20 to 570-630 Nm
(420-465lbf ft). Stake the nut by splitting axially and
bending into the notches on the pinion.
12
Example
Add pre-load 0.05 mm
Total 0.50mm
Replace the 1.5 mm shim by a 1.0 mm shim
d Check the rolling torque of pinion bearings

(without oil seal), using a torque meter driving a
socket fitted to nut 20. The reading should be:
For new bearings 2-4 Nm (18-35 lbf inch)
For re-used bearings 1-2 Nm (9-18 lbf inch)
If the rolling torque is too high, increase the shim

thickness. If the rolling torque is too low, decrease
the shim thickness.
Fig 91.
1-76 9803/8070-1 1-76

Section 1 - 1
Front Axle
Drive Head
1
3 4
2
6
A 5
9 10
8
7
14
17 18 16 11
12
13 19 15 B
Fig 92.
15 Fit inner races of bearings 16 and 19 to differential 19 Fit both castellated nuts 13 and 14. Tighten both nuts
case spigots (if previously removed) while turning equally to seat all components, then slacken back nut
them continuously. 13 so that a notch is aligned with the hole for roll pin
12. Position a D.T.I. to check bearing end play as
16 Locate differential case assembly 15 into the housing. shown at E. Slacken nut 14 until there is a little end
Locate the differential lock end first by rotating the play in the bearings then retighten until there is no
assembly about the differential lock housing. end play and a notch is aligned with the hole for screw
11.
17 Position split bearing carrier 18. Apply JCB
Threadlocker and Sealer to the threads of bolts 17. Fit
bolts but do not fully tighten. Fit bearing cup 19 and
when correctly seated, torque tighten bolts 17 to 315-
345 Nm (232-254 lbf ft).
18 Rotate drive head through 90° so that the differential

lock housing is uppermost. Tap bearing cup 16 into
position over its inner race.
1-77 9803/8070-1 1-77

Section 1 - 1
Front Axle
Drive Head
Fig 93.
20 Tighten one of the nuts 13 or 14 by one complete turn

to provide bearing pre-load.
Fig 94.
21 Using a D.T.I. with a magnetic base, check the crown

wheel backlash as shown at F. This should be 0.20 -
0.28 mm (0.008-0.011 in). To achieve this figure, back
off one of the castellated nuts and tighten the other
one by the same number of notches. It is
recommended that backlash is checked in four
diametrically opposed places.
1-78 9803/8070-1 1-78

Section 1 - 1
Front Axle
Drive Head
1
3 4
2
6
A 5
9 10
8
7
14
17 18 16 11
12
13 19 15 B
Fig 95.
22 Apply engineers' marker to 3 or 4 teeth then check the 26 Fit new 'O' rings 3 and 4 to piston back plate 2. Fit
crown wheel and pinion for correct meshing. back plate 2 over piston 5.
K Crown Wheel and Pinion Adjustment ( T 1-82)
If this is incorrect, adjust nuts 13 and 14 and shim 27 27 Gently tap the differential lock assembly with a soft
accordingly. faced hammer to seat all components.
23 Fit screw 11 and roll pin 12. 28 Ensure that the groove A in the piston 5 lines up with
screw 11.
24 Position the drive head with the differential lock
housing uppermost. Fit new 'O' ring 6 to piston 5. 29 Compress the assembly sufficiently to fit circlip 1.
Sub-assemble piston 5, end plate 10, axial roller
bearing 9, thrust sleeve 8 and compression spring 7. 30 Using a hand pump, test the differential lock for
correct operation and leaks. Do not exceed a
25 Grease the differential lock housing bore and fit sub- pressure of 35 bar (500 lbf/in).
assembly over differential lock actuator. Make sure
that the piston is inserted squarely into the bore.
1-79 9803/8070-1 1-79

Section 1 - 1
Front Axle
Drive Head
Pinion Depth
Fig 96.
The following dimensions are required to do the pinion Dimension A should be stamped on the drive head flange
depth shim calculation: F, otherwise it must be measured. To do this, bolt a rigid
flat plate P onto the differential bearing housing flange as
shown and take the measurement A from the underside of
Dimension A As stamped on the housing or measured
the plate to the seating surface of the pinion bearing outer
Dimension B A standard dimension corrected by the race 26 (e.g.198 mm).
deviation figure on the pinion
Dimension D Measured The standard dimension B for the front axle is 162 mm.
1-80 9803/8070-1 1-80

Section 1 - 1
Front Axle
Drive Head
From the face of the pinion obtain the etched deviation
figure which is in units of 0.1mm (e.g. `+2' etched on the
pinion denotes +0.2 mm).
If positive, add this to standard dimension B.
If negative, subtract this from standard dimension B.
The result is the corrected dimension B (e.g. 162.2 mm).
Measure the depth D of assembled bearing outer race 26

and bearing inner race 30, (e.g. 35.59 mm).
Obtain the theoretical shim thickness S by the following

calculation:
S = A minus B (corrected) minus D.
Add 0.05 to the theoretical thickness S to compensate for

pre-load. The result will be the thickness of shims 27
required behind the pinion bearing outer race 26.
Example Calculation (all dimensions in millimetres)
Dimension A 198.00
Minus Corrected Dimension B 162.20
= 35.80
Minus Bearing Depth D 35.59
= 0.21
Plus Pre-load 0.05
TOTAL 0.26
Use shim pack size to the nearest 0.10mm which in this

example is 0.30mm.
1-81 9803/8070-1 1-81

Section 1 - 1
Front Axle
Drive Head
Crown Wheel and Pinion Adjustment
Meshing of the gears should be checked by marking three

of the pinion teeth with engineers' marking compound and
rotating the pinion.The marking will then be transferred to
the crown wheel teeth.
Fig 99. Pinion too far out of mesh
Increase the thickness of shim 27 between the pinion inner

bearing cup and the axle casing. K Fig 89. ( T 1-75) Move
Fig 97. Correct tooth marking. the crown wheel away from the pinion to correct the
backlash.
Fig 98. Pinion too deeply in mesh
Decrease the thickness of shim 27 between the pinion

inner bearing cup and the axle casing. K Fig 89. ( T 1-75)
Move the crown wheel towards the pinion to correct the
backlash.
1-82 9803/8070-1 1-82

Rear Axle
P T N
Fig 100.
Removal !MWARNING
Raised Equipment
!MWARNING Never walk or work under raised equipment unless it
Make the machine safe before getting beneath it. Park is supported by a mechanical device. Equipment
the machine on level ground and lower the which is supported only by a hydraulic device can
attachments. Stop the engine and remove the starter drop and injure you if the hydraulic system fails or if
key. Make sure the park brake is engaged. Disconnect the control is operated (even with the engine stopped).
the battery to prevent the engine being started. Block 13-2-3-7_2
all four wheels before getting under the machine.
1 Remove any mounted implements.
3-3-1-1
2 Jack up or hoist the chassis to take all load off the

!MWARNING axle. Support the chassis with stands. Leave the
This component is heavy. It must only be removed or wheels on the axle. Position a jack under the pick-up
handled using a suitable lifting method and device. hitch to steady the axle
BF-4-1_1
F-83 9803/8070-1 F-83

Rear Axle
3 Drain oil from the hubs/axle.
4 Disconnect the axle mounted speed sensor flying

leads A, one at each hub, from their chassis mounted
mating connectors. Tie the cable sheathing to the
axle for protection during the following procedure. E
5 Disconnect brake pipes B, hydraulic hoses and
connections C and D. Ensure that all opened
connections are sealed to prevent loss of fluid and
ingress of dirt.
B A
C030310
Fig 103.
6 Remove the mounting bolts E for the quick release

coupling and rotary position sensor brackets. Lay the
brackets on the chassis with hoses still connected.
7 Disconnect the 'V' link arms S at the top of the axle.

C
8 Remove driveshafts (i.e. main drive and PTO).
9 Disconnect the lower pin of the two suspension

cylinders N.
Fig 101.
10 Remove the clamps/bushes P securing anti-roll bar to
the axle
11 Disconnect the two control arms T at the axle end.

D
12 If necessary, raise the chassis to allow clearance for
the axle and pull the axle clear
Replacement
Replacement is the reverse of the removal procedure.
Ensure that the chassis is correctly supported as
described previously. K Removal ( T F-83)
Treat all bolt threads with JCB Threadlocker and Sealer.

Fig 102.
See the relevant Removal and Replacement pages for
correct fitting procedures and torque settings of the
following:
1 Cylinders N, see Section S
F-84 9803/8070-1 F-84

Rear Axle
2 Anti-roll bar P, see Section S
3 Control arms T, see Section S
4 Drive shafts, see Drive shafts, Section F
Bleed the brakes, see Section G
Set the ride height see Section S.
On completion, fill the axle with the correct oil, see Fluids,
Lubricants and Capacities, Section 3.
F-85 9803/8070-1 F-85

Rear Axle
Hub
Hub
16 18 19 7 28 27 26
15
6
25
3
20
17
2 31
34 24
38 11
12
13
4
8
9
10 21
14 22
1 23
Fig 104.
Component Key 7 Hub

8 Circlip
1 Screw 9 Sun gear
2 Cover 10 Thrust washer
3 O ring 11 Drive shaft
4 Backing plate 12 Circlip
5 Screw 13 Lock plate
6 Gear carrier 14 Ring nut
F-86 9803/8070-1 F-86

Rear Axle
Hub
15 Ring gear
16 Circlip
17 Ring gear support
18 Outer wheel bearing
19 O ring
20 Bolt
21 Nut
22 Spacer
23 Brake disc
24 Spacer
25 Bolt
26 Pole wheel
27 Seal
28 Inner wheel bearing
31 Sleeve
34 Side gear pin
38 Side Gear
F-87 9803/8070-1 F-87

Rear Axle
Hub
Dismantling
Fig 105.
1 If not already done, drain the oil from the axle and 10 Remove the ring nut 14 using an accurately fitted tool
hub. (see Service Tools)
2 Remove the service brake calliper units from the 11 Suitably support the hub 7 and pull out the ring gear
axle.(See Footbrake Callipers, Section G). assembly 15.
3 Remove the six screws 1 and, using the three tapped

holes provided, use screws to pull off the cover 2.
Remove and discard O-ring 3.
4 Pull out the axle shaft backing plate 4 using a puller

screw (M8).
5 Remove the screws 5 and, suitably supporting the

side gear carrier 6, pry the carrier 6 from the wheel
hub 7, using levers in the recesses provided.
6 Remove the circlip 8 retaining the sun gear 9 on the

drive shaft 11 and pull out the sun gear.
7 Remove the thrust washer 10.
8 Remove the drive shaft 11.
9 Pull out the circlip 12 securing the ring nut lock plates
13. Remove the lock plates. Fig 106.
F-88 9803/8070-1 F-88

Rear Axle
Hub
12 Pry off the circlip 16 from the ring gear 15 using a
suitable screwdriver.
13 Disassemble the ring gear support 17 from the ring

gear 15.
14 If the replacement of the outer wheel bearing 18 inner

race is necessary, the bearing may be removed by a
suitable puller or by a remover that can be inserted in
the holes of the ring gear support 17.
Fig 107.
Fig 108.
15 Pull out the complete wheel hub 7. Remove and 18 Pry out the seal 27 from the wheel hub and remove
discard the O-ring 19. the inner race of the inner wheel bearing 28.
16 Remove the bolts 20, nuts 21, spacers 22, brake disc 19 Using a suitable press, press out the outer races of
23 and spacer 24. the outer wheel bearing 29 and inner wheel bearing
30 from hub 7.
17 Remove bolts 25 and pole wheel 26.
F-89 9803/8070-1 F-89

Rear Axle
Hub
20 If the sleeve 31 is damaged, it can be removed by
undoing the fixing screws 32 and removing the
calliper support 33.
Fig 109.
DR
AIN
LEVEL
OIL
Fig 110.
21 Mark the side gear pins 34 and their seating area on 24 Remove the side gears 38 and corresponding thrust
the carrier 6 for identification of original position at re- washers 39.
assembly.
Inspection
22 Arrange the carrier 6 on wooden blocks and, using a
suitable press, push out the pins 34. Thoroughly wash all the metallic parts using a solvent,
23 Pick up all the needle rollers 35 and spacers36. air. Pay particular attention to the internal lubrication
Note: It is important to keep matched needle rollers and be spotlessly clean.
thrust washers 37 with corresponding pins 34, because of
predetermined assembly tolerance limits.
F-90 9803/8070-1 F-90

Rear Axle
Hub
Check that the housings and the covers show no
scoring or ridging.
show no signs of wear or spalling. The contact area must
extend over the whole surface of the teeth and must look
smooth and uniform. Renew all gears showing signs of
such defects.
Check that the shimming surfaces of the gears, the

spacers and the shoulder rings show no signs of snagging
or seizure.
Check the threading and the grooving on the shafts are in

good condition.
F-91 9803/8070-1 F-91

Rear Axle
Hub
Assembly that they are correctly seated. Position the inner race
of the inner wheel bearing 28 before fitting lip seal 27.
Note: Before assembly, all oil seals for rotating parts
should be soaked in axle oil for half an hour.
27 X 2 mm
Fig 113.
3 Smear JCB Multigasket (see Section 1) on the outer

rim of seal 27 and fit the seal to the dimension shown
at X. Apply grease to the seal lips. Lubricate and fit a
new O-ring 19.
Fig 111.
1 Smear JCB Multigasket (see Section 1) on the axle

cast joining flange, fit sleeve 31, mounting plate 33
and tighten screws 32 to 900-90 Nm (663-730 lb ft).
Fig 112.
2 Fit the outer races of the wheel inner and outer

bearings 28 and 30 into the wheel hub 7, ensuring
F-92 9803/8070-1 F-92

Rear Axle
Hub
Fig 114.
4 Fit spacer 24, brake disc 23, spacers 22, nuts 21 and
bolts 20. Tighten bolts 20 and nuts 21 to 620-680 Nm
(457-502 lbf ft). Fit pole wheel 26 and bolts 25,
tightened to 33-37 Nm (24-27 lbf ft).
Fig 115.
5 Mount the support 17 in the ring gear 15 and secure

with the circlip 16.
F-93 9803/8070-1 F-93

Rear Axle
Hub
Fig 116.
6 Suitably support the wheel hub 7 to prevent damage the wheel bearings by setting the rolling force as
to seal 27 and mount the hub and ring gear follows:
assemblies onto the sleeve 31.
Note: To prevent wrong measurement of rolling force, it is
advisable to seat the bearings properly before
measurement by revolving the wheel hub repeatedly.
Measure the rolling force required to maintain rotation

of the hub using cord wrapped around the wheel
studs and a force meter as shown. Ignore the extra
force needed to start rotation. Check the alignment for
the lock plates 13 and adjust the nut 14 to achieve a
pull load of 177 to 216 N (40 to 49 lbf).
Fig 117.
7 Tighten the ring nut 14 using an accurately fitted tool

(see Service Tools) to reach the correct pre-load for
F-94 9803/8070-1 F-94

Rear Axle
Hub
8 Insert the lock plates 13 and fit the circlip 12.
Fig 118.
49 52 50 51 50
53 54
DR
LEVEL
AIN
OIL
Fig 119.
9 Arrange the three side gears 38 in their seats in the 11 Position the outer thrust washers 37 on the side gears
side gear carrier 6. and align holes.
Note: Two rows of needle rollers of the same selection 12 Insert and force fit pins 34, making sure that the
class should be used for replacement on each single side rollers are not dislodged.
gear pin.
10 Insert the inner thrust washers 39. Smear the pin

lower portion (head end) with grease and position the
first row of needle rollers 35. Fit the spacers 36.
Smear the pin upper portion with grease and position
the second row of needle rollers 35.
F-95 9803/8070-1 F-95

Rear Axle
Hub
Fig 120.
13 Fit the drive shaft 11.
14 Insert the thrust washer 10.
15 Insert the sun gear 9 and secure with the circlip 8.
16 Mount the side gear carrier assembly 6 onto the hub.

tightening the fixing screws 5 to 67-74 Nm (49-54 lbf
ft).
17 Fit drive shaft backing plate 4.
18 Lubricate and fit O-ring 3.
19 Rotate and align pins 34 to allow mounting of cover

2. Fit cover 2. The cover locks the pins, preventing
them rotating.
20 Smear fixing screws 1 with sealing compound, then

21 Ensure the axle is filled with the correct oil (see

Fluids, Lubricants and Capacities, Section 3)
F-96 9803/8070-1 F-96

Rear Axle
Drive Head
Drive Head
Fig 121.
Important: The axle must be removed from the machine

first because the drive head is too heavy to remove with
!MWARNING
the axle in situ. K Removal ( T 1-50) Make the machine safe before getting beneath it. Park
!MWARNING attachments. Stop the engine and remove the starter
key. Make sure the park brake is engaged. Disconnect
This component is heavy. It must only be removed or the battery to prevent the engine being started. Block
handled using a suitable lifting method and device. all four wheels before getting under the machine.
BF-4-1_1 3-3-1-1
Removal
1 Drain the oil from hubs/axle.
2 Remove the two bolts 1. Lever off the planet gear

carrier 2 at one end of the axle, at levering points
provided. Remove and discard the Ò' ring.
F-97 9803/8070-1 F-97

Rear Axle
Drive Head
K Dismantling ( T 1-54) Repeat for the other end of
the axle.
3 Pull the driveshafts out of the axle.
4 Remove the PTO input shaft. K Rear PTO Input

Shaft ( T F-114)
5 Position the axle so that the input shafts are pointing

upwards.
Fig 122.
6 Remove bolts 3 and lift the drive head 4 from the axle.
7 Remove two dowels from the axle, if loose.
Replacement
Replacement is the reverse of the removal procedure
Treat all mating surfaces with JCB Multigasket.
Treat bolts 3 with JCB Threadlocker and Sealer. Tighten to

a torque of 285 - 315 Nm (210 - 232 lbf ft).
Tighten the two bolts 1 to a torque of 67 - 74 Nm (50 - 54

lbf ft).
F-98 9803/8070-1 F-98

Rear Axle
Drive Head
Component Key
18 6 5 8 2 4 10 9 1 3 21
7
25
15
39
37
40
44 41
46 43
45 28
47
48
49
12
52 50 11 16 17 24 51 32 33 35 34 30 29 26 27
Fig 123.
1 Circlip 15 Screw
2 Piston back plate 16 Roll pin
5 Piston 21 Oil passage dowel
6 O ring 24 Bearing
7 Spring 25 Bearing
8 Thrust sleeve 26 Pinion nut
9 Roller bearing 27 Drive flange
10 End plate 28 Pinion shaft
11 Screw 29 Oil seal
12 Crown wheel guard 30 Bearing
F-99 9803/8070-1 F-99

Rear Axle
Drive Head
32 Bearing
33 Pinion bearing depth shim
34 Pinion bearing pre-load shim
35 Spacer
37 Bolt
39 Differential lock actuating sleeve
40 Counter plate
41 Friction plate
43 Shim
44 Pinion gear
45 Trunnion pin
46 Bevel gear
47 Shim
48 Pinion gear
49 Shim
50 Differential case
51 Bolt
52 Crown wheel
F-100 9803/8070-1 F-100

Rear Axle
Drive Head
Dismantling
Fig 124.
!MWARNING 3 Apply compressed air to the oil feed port B to force

out the piston back plate 2 from the differential lock
This component is heavy. It must only be removed or housing. Remove and discard 'O' rings 3 and 4.
BF-4-1_1 4 Remove piston 5. Remove 'O' ring 6 and discard.
1 Remove the drive head from the axle K Removal 5 Remove compression spring 7, thrust sleeve 8, axial
and Replacement ( T 1-66) Secure it in a vice or roller bearing 9 and end plate 10.
suitable jig for dismantling and examination.
6 Remove three screws 11 and crown wheel guard 12.
2 Fit tool to retain differential lock assembly. (see
Service Tools). Remove circlip 1 from the differential 7 Remove bolts 13 and 14.
lock housing.
F-101 9803/8070-1 F-101

Rear Axle
Drive Head
8 Remove the anti-rotation screw 15 and roll pin 16 Note: During a differential lock repair or piston
from the castellated nuts. Remove castellated nuts 17 replacement, inspect the housing for scores, marks or
and 18; remove the split bearing carriers 19 and 20. damage which could cause a leak. If necessary, polish the
housing with oil-lubricated 800 grade or fine abrasive
9 Remove the oil passage dowel 21. Remove and paper to remove any marks. Alternatively, renew the
discard O-rings 22. housing.
10 Remove the differential assembly 23 with bearings 24

and 25.
Fig 125.
11 Remove the pinion nut 26. Discard the nut. 16 Tap out the bearing cup 32 from the opposite bearing
housing and remove the pinion bearing depth shim
12 Remove the drive flange 27. 33.
13 Drive the pinion shaft 28 out of the drive head carrier. 17 Remove the pinion bearing pre-load shim 34, spacer
35 and bearing 36 from the pinion shaft.
14 Prise the shaft seal 29 out of the bore.
15 Remove the taper roller bearing 30 and tap out the

bearing cup 31.
F-102 9803/8070-1 F-102

Rear Axle
Drive Head
Fig 126.
18 Remove the bolts 37 and separate the differential lock Inspection

case 38 from the rest of the assembly.
19 Remove actuating sleeve 39. biodegradable if possible, and blow them with compressed
air.
20 Remove 7 counter plates 40 and 6 friction plates 41
from the differential pinion gear 44. Check that the housings show no indentations and that the
bearing seats are intact, without scoring or ridging.
21 Separate the differential case halves 42 and 50.
22 Remove the pinion gears 44 and 48, bevel gears 46, show no signs of wear or spalling. Renew all gears
trunnion pin 45, and thrust washers 47 from the case showing signs of such defects.
halves. Remove the thrust washers 43 and 49 from
both case halves. Check that the shimming surfaces of the bearings and
spacers show no signs of snagging or seizure.
23 Remove bolts 51 and separate differential assembly
from the crown wheel 52. Check the threading and the grooving on the shafts are in
good condition.
F-103 9803/8070-1 F-103

Rear Axle
Drive Head
Check the mating faces of crown wheel and differential
case. These must be perfectly smooth or fretting will cause
the bolts to work loose.
Note: The bevel gears are a matched set, as are the two
differential case halves also the crown wheel and pinion.
These must be renewed as sets if any of their components
are damaged or excessively worn. Do not use unmatched
components.
Note: The differential case halves are stamped for

matching purposes. The stamp on the crown wheel case
half can only be seen when the crown wheel is removed.
F-104 9803/8070-1 F-104

Rear Axle
Drive Head
Assembly
Fig 127.
To enable fitting of inner races of bearings 24, 25 and 26 over the counter and friction plates and align the bolt
pre-heat to 90-110 deg C in oil or in an oven. Do not use a holes with those of the differential case half 42.
flame. Before assembly, lightly oil all bearings and soak all
seals for rotating parts in axle oil for half an hour. 5 Check free rotation of the gears in the horizontal
position (If held vertically the friction and counter
1 Assemble the trunnion pin 45, bevel gears 44, 46, 48, plates would prevent rotation).
and their thrust washers 43, 47 and 49 into the
differential case half 50. 6 Fit crown wheel 52 using new bolts 51 and tighten to
450-480 Nm (332-354 lbf ft). Tighten bolts 37 to 115-
2 Position the differential case half 42 aligning the 130 Nm (85-96 lbf ft) and check free rotation of the
match mark letters. gears in the horizontal position (see previous step).
3 Fit 7 counter plates 40 and 6 friction plates 41,

starting and finishing with a counter plate. Make sure
the counter plate tabs are aligned.
4 Position the actuating sleeve 39 on top of the last

counter plate. Position the differential lock case 38
F-105 9803/8070-1 F-105

Rear Axle
Drive Head
Fig 128.
7 Fit bearing cup 32 in the drive head housing with the

correct thickness of shims 33 as calculated for pinion
depth setting. K Pinion Depth ( T F-111)
8 Fit pinion bearing 36 onto pinion 28. Fit pinion into

housing.
9 Fit bearing spacer 35, outer race 31 and a thick

enough pre-load shim 34 (e.g 1.5 mm) to provide end
play in the bearings.
10 Fit bearing inner race 30, drive flange 27 (without oil

seal) and tighten nut 26 to 570-630 Nm (420-465lbf
ft).
11 Check and adjust pinion bearing pre-load as follows:
a Position a dial test indicator (D.T.I.) C as shown.

Zero the D.T.I.
Fig 129. b Lift the pinion as far as possible and note the D.T.I.
reading.
F-106 9803/8070-1 F-106

Rear Axle
Drive Head
c Add a pre-load of 0.05 mm to the D.T.I. reading
and subtract the total from the existing shim
thickness (e.g 1.5 mm). The result is the thickness
of shim to be fitted in place of the existing 1.5mm
shim.
12
Example
Add pre-load 0.05 mm
Total 0.50mm
Replace the 1.5 mm shim by a 1.0 mm shim
d Check the rolling torque of pinion bearings

(without oil seal), using a torque meter driving a
socket fitted to nut 26. The reading should be:
For new bearings 2-4 Nm (18-35 lbf inch)
For re-used bearings 1-2 Nm (9-18 lbf inch)
If the rolling torque is too high, increase the shim

thickness. If the rolling torque is too low, decrease
the shim thickness.
Fig 130.
13 When pinion bearing pre-load is correct, remove the

drive flange and fit seal 29 to the dimension shown at
D. Apply grease to the inner lips of the seal.
14 Fit drive flange and tighten nut 26 to 665-735 Nm

(490-540 lbf ft). Stake the nut by splitting axially and
bending into the notches on the pinion.
F-107 9803/8070-1 F-107

Rear Axle
Drive Head
Fig 131.
15 Renew Ò' rings 22 and fit oil passage dowel 21.
16 Fit bearings 24 and 25 to differential case spigots (if

previously removed) while turning them continuously.
Locate differential case assembly 23 into the housing.
17 Position split bearing carriers 19 and 20. Apply JCB

Threadlocker and Sealer to the threads of bolts and
14and tighten to 315-345 Nm (232-254 lbf ft).
18 Fit both castellated nuts 17 and 18. Tighten both nuts

equally to seat all components, then slacken back nut
17 so that a notch is aligned with the hole for roll pin
16. Position a D.T.I. to check bearing end play as
shown at E. Slacken nut 18 until there is a little end
play in the bearings then re tighten until there is no
end play and a notch is aligned with the hole for screw
15. Fig 132.
F-108 9803/8070-1 F-108

Rear Axle
Drive Head
19 Tighten one of the nuts 17 or 18 by one complete turn
to provide bearing pre-load.
Fig 133.
20 Using a D.T.I. with a magnetic base, check the crown

wheel backlash as shown at F. This should be 0.20 -
0.28 mm (0.008-0.011 in). To achieve this figure, back
off one of the castellated nuts and tighten the other
one by the same number of notches. It is
recommended that backlash is checked in four
diametrically opposed places.
F-109 9803/8070-1 F-109

Rear Axle
Drive Head
Fig 134.
21 Apply engineers' marker to 3 or 4 teeth then check the 25 Fit new 'O' rings 3 and 4 to piston back plate 2. Fit
crown wheel and pinion for correct meshing. . If this is back plate 2 over piston 5.
incorrect, adjust nuts 17 and 18 and shim 33
accordingly. K Crown Wheel and Pinion 26 Gently tap the differential lock assembly with a soft
Adjustment ( T F-113) faced hammer to seat all components.
22 Fit screw 15 and roll pin 16. 27 Ensure that the groove A in the piston 5 lines up with
screw 15.
23 Position the drive head with the differential lock
housing uppermost. Fit new 'O' ring 6 to piston 5. 28 Compress the assembly sufficiently to fit circlip 1.
Sub-assemble piston 5, end plate 10, axial roller
bearing 9, thrust sleeve 8 and compression spring 7. 29 Using a hand pump, test the differential lock for
correct operation and leaks. Do not exceed a
24 Grease the differential lock housing bore and fit sub- pressure of 35 bar (500 lbf/in).
assembly over differential lock actuator. Make sure
that the piston is inserted squarely into the bore.
F-110 9803/8070-1 F-110

Rear Axle
Drive Head
Pinion Depth
Fig 135.
The following dimensions are required to do the pinion From the face of the pinion obtain the etched deviation
depth shim calculation: figure which is in units of 0.1mm (e.g. `+2' etched on the
pinion denotes +0.2 mm).
Dimension A As stamped on the housing or measured
If positive, add this to standard dimension B.
Dimension B A standard dimension corrected by the
deviation figure on the pinion If negative, subtract this from standard dimension B.
Dimension D Measured
The result is the corrected dimension B (e.g. 208.2 mm).
Dimension A should be stamped on the drive head flange
F, otherwise it must be measured. To do this, bolt a rigid Measure the depth D of assembled bearing outer race 32
flat plate P onto the differential bearing housing flange as and bearing inner race 36, (e.g. 35.59 mm).
shown and take the measurement A from the underside of
the plate to the seating surface of the pinion bearing outer Obtain the theoretical shim thickness S by the following
race 32 (e.g.244 mm). calculation:
The standard dimension B for the rear axle is 208 mm. S = A minus B (corrected) minus D.
F-111 9803/8070-1 F-111

Rear Axle
Drive Head
Add 0.05 to the theoretical thickness S to compensate for
pre-load. The result will be the thickness of shims 33
required behind the pinion bearing outer race 32.
Example Calculation (all dimensions in millimetres)
Dimension A 244.00
Minus Corrected Dimension B 208.20
= 35.80
Minus Bearing Depth D 35.59
= 0.21
Plus Pre-load 0.05
TOTAL 0.26
Use shim pack size to the nearest 0.10mm which in this

example is 0.30mm.
F-112 9803/8070-1 F-112

Rear Axle
Drive Head
Crown Wheel and Pinion Adjustment
Meshing of the gears should be checked by marking three

of the pinion teeth with engineers' marking compound and
rotating the pinion.The marking will then be transferred to
the crown wheel teeth.
Fig 138. Pinion too far out of mesh
Increase the thickness of shim 33 between the pinion inner

bearing cup and the axle casing. K Fig 128. ( T F-106)
Fig 136. Correct tooth marking. Move the crown wheel away from the pinion to correct the
backlash.
Fig 137. Pinion too deeply in mesh
Decrease the thickness of shim 33 between the pinion

inner bearing cup and the axle casing.
K Fig 128. ( T F-106) Move the crown wheel towards the
pinion to correct the backlash.
F-113 9803/8070-1 F-113

Rear Axle
Drive Head
Rear PTO Input Shaft Replacement
Removal 1 Fit bearing 5 onto shaft 6.
1 Disconnect the drive shaft from the transmission to 2 Install shaft and bearing into the housing and fit circlip
the PTO input shaft. 4.
2 Prevent the flange 1 from turning using a suitable bar 3 Fit new oil seal 3.
reacting against two bolts refitted into the flange.
Unscrew nut 2. 4 Fit flange 1 and nut 2.
3 Remove flange and prise out seal 3. 5 Prevent the shaft from turning using a suitable bar
reacting against two bolts refitted into the flange.
4 Remove circlip 4, bearing 5 and shaft 6. Tighten nut 2 to 570 to 630 Nm (420 to 465 lb ft).
Fig 139.
Fig 140.
F-114 9803/8070-1 F-114

Rear Axle
Rear PTO Gearbox
Rear PTO Gearbox
Fig 141.
F-115 9803/8070-1 F-115

Rear Axle
Rear PTO Gearbox
Component Key 49 O ring

50 O ring
1 Sensor 51 O ring
2 Nut 52 Oil pipe
3 Output shaft
4 Bolt
8 Circlip
9 Bearing
10 Screw
11 Selector support
13 Adjustment spacers
15 Driving gear
16 Circlip
17 Bearing
18 Screw
19 Flange
20 Spacer
21 O ring
22 Oil seal
24 Bearing
25 Nut
26 Bearing
27 Shoulder ring
28 Bush
29 Roller cage
30 Spacer
31 Driven gear
32 Hub
33 Sleeve
36 Driven gear
37 Shaft
39 Nut
40 Circlip
41 Retainer
42 Outer spring
43 Inner spring
46 Piston
47 Screw
48 Selector fork
F-116 9803/8070-1 F-116

Rear Axle
Rear PTO Gearbox
Dismantling
!MWARNING
BF-4-1_1
1 Drain oil from rear axle (see Section 3).
Fig 143.
4 Fit a suitable retaining plate A to prevent the gears

from moving when the rear cover is removed.
5 Remove nineteen bolts 4, leaving two bolts 5 in

Fig 142. position until the weight of the cover is safely
supported by a hoist at B.
2 Remove sensors 1 and 1a.
6 Remove the remaining bolts 5, pull the cover
3 Remove the eight nuts 2 and remove the PTO output backwards and lift clear
shaft 3.
F-117 9803/8070-1 F-117

Rear Axle
Rear PTO Gearbox
Fig 144.
7 Remove screws 6 and oil conveyor 7.
8 Remove circlip 8 and extract bearing sleeve 9.
9 Remove screws 10.
10 Support the gears 12 and remove plate A.
11 Remove selector 11 and gear assembly 12 together,

collecting the adjustment spacer(s) 13. Retain the
spacers for assembly.
F-118 9803/8070-1 F-118

Rear Axle
Rear PTO Gearbox
Fig 145.
12 Remove screws 14 and guard 14a.
13 Extract driving gear 15.
14 Remove circlip 16 and remove bearing 17 from

driving gear 15.
15 Remove screws 18 and extract flange 19, collecting

the adjustment spacer(s) 20.
16 Remove Ò' ring 21 and seal 22 from the flange.
17 Remove Ò' rings 23.
18 Drive bearing race 24 out of the cover.
F-119 9803/8070-1 F-119

Rear Axle
Rear PTO Gearbox
Fig 146.
19 Support the shaft and gear assembly and unscrew 23 Remove gear 36 and extract roller cage 35 and
nut 25. spacer 34 from the gear.
20 Remove bearing inner race 26, and shoulder ring 27. 24 Extract bearing inner race 38 from shaft 37.
21 Remove gear 31 and extract bush 28, roller cage 29 25 Check condition of studs A. These should be held by
and spacer 30 from the gear. retaining compound.
22 Remove sleeve 33 and hub 32.
Fig 147.
26 Remove nuts 39. Extract circlip 40 and remove 27 Remove screw 47 and extract fork 48 and piston 46
springs 42, 43 and retainers 41, 44. from the support 45. Remove Ò' rings 49, 50 and 51.
F-120 9803/8070-1 F-120

Rear Axle
Rear PTO Gearbox
Check the threading and the grooving on the shafts are in
good condition
Check the sides of the sliding sleeve for wear, along with
the contact surfaces of the gear selector fork.
Assembly
!MWARNING
BF-4-1_1
Fig 148.
28 If necessary, remove pipes 52, 53 and oil deflectors

55, 56.
29 If bearing outer race 54 needs renewal, remove it

using an extractor.
Inspection
air. Pay particular attention to the internal lubrication
be spotlessly clean. Fig 149.
Check that the housings and the covers show no 1 Fit bearing outer race 54.
scoring or ridging. 2 Fit oil deflectors 55 and 56. Tighten screws 57 to 9-11
Nm (7-8 lbf ft).
show no signs of wear or spalling. The contact area must 3 Fit pipes 52 and 53. Tighten the connections to 19-21
extend over the whole surface of the teeth and must look Nm (14-15 lbf ft). Test the sealing of the circuit using
smooth and uniform. Renew all gears showing signs of a hand pump. A pressure of 30 bar (435 lbf/in2)
such defects. should be maintained over a period of 30 minutes.
Check that the spacers and shoulder rings show no signs

of snagging or seizure.
F-121 9803/8070-1 F-121

Rear Axle
Rear PTO Gearbox
Fig 150.
4 Fit new Ò' rings 49, 50 and 51.
5 Locate retainer 44, springs 42 and 43 and retainer 41

in the support 45. Secure with circlip 40.
6 Locate piston 46 and fork 48 in the support 45. Apply

retaining compound when fitting screw 47.
7 Fit nuts 39 and adjust to achieve a piston stroke of 8.5

mm (0.33 in).
F-122 9803/8070-1 F-122

Rear Axle
Rear PTO Gearbox
Fig 151.
8 Fit bearing outer race 24 into the cover.
9 Fit bearing inner races 26 and 38 onto the shaft 37.
10 Position spacer(s) 20 and fit flange 19.
11 To set the bearing pre-load, fit the cover and shaft 37

without the gears as shown.
12 Make up and fit a suitable tool A to allow the shaft to

be rotated using a torque meter.
13 Check that the rolling torque of shaft 37 is 1-2 Nm (9-

17 lbf in). If the rolling torque is incorrect, adjust the
thickness of spacers 20 and recheck the rolling torque
until it is correct.
14 When the rolling torque is correct, remove the flange,

cover and shaft. Retain the determined thickness of
spacers for re-assembly. Remove bearing inner race
26 from the shaft.
F-123 9803/8070-1 F-123

Rear Axle
Rear PTO Gearbox
Fig 152.
15 Fit roller cage 35 and spacer 34 into gear 36 and fit

the gear onto shaft 37.
16 Fit hub 32 and sleeve 33 onto the shaft.
17 Fit spacer 30, roller cage 29 and bush 28 into gear 31

and fit the assembly onto the shaft.
18 Fit shoulder ring 27, bearing inner race 26 and tighten

nut 25 to 665-735 Nm (490-540 lbf ft). Stake the nut
into the groove on the shaft.
19 Fit bearing 17 and circlip 16 onto gear 15.
20 Fit gear 15 into the cover.
21 Fit guard 14a. Tighten screws 14 to 9-11 Nm (7-8 lbf

ft).
22 Fit new Ò' rings 23.
Fig 153.
F-124 9803/8070-1 F-124

Rear Axle
Rear PTO Gearbox
Fig 155.
27 Make up a suitable retaining plate C and secure the

gear and shaft assemblies as shown.
Important: It is essential that the retaining plate is fitted to

make the assembly procedure safe and easy.
Fig 154.
23 Fit spacer(s) 13 to the same thickness as removed

when dismantling.
24 Apply a little grease to the selector support 11 to ease

its assembly into the cover.
25 5Locate the selector fork onto sleeve 33.

K Fig 152. ( T F-124) Enter the shaft, gears and
selector assemblies into the cover.
26 Apply retaining compound to screws 10 and tighten to

73-77 Nm (54-57 lbf ft).
F-125 9803/8070-1 F-125

Rear Axle
Rear PTO Gearbox
Fig 156.
28 Fit bearing inner race 9 and secure with circlip 8.
29 Position guard 7, apply retaining compound to screws

6 and tighten to 9-11 Nm (7-8 lbf ft).
F-126 9803/8070-1 F-126

Rear Axle
Rear PTO Gearbox
Fig 157.
30 Lubricate and fit new Ò' ring 21 and oil seal 22.
Smear grease on the inner diameter of the seal.
31 Position the correct thickness of adjustment spacers

20 as determined when checking rolling torque.
32 Fit flange 19, apply retaining compound to screws 18

and tighten to 73-77 Nm (54-57 lbf ft).
33 To prevent the gears from moving and allow plate C

to be removed, fit the retaining plate A (as used
during dismantling).
34 Remove retaining plate C.
35 Clean the mating faces of cover and housing and

apply sealing compound as shown.
Fig 158.
F-127 9803/8070-1 F-127

Rear Axle
Rear PTO Gearbox
Fig 160.
38 Fit output shaft 3. Tighten nuts 2 to 63-67 Nm (47-50

lbf ft).
Fig 159.
39 Apply sealing compound to threads of sensors 1 and
1a. Tighten to 22-24 Nm (16-18 lbf ft).
36 Fit the cover using twentyone new self-locking bolts 4;
40 Refill the rear axle and PTO with the specified oil (see
Section 3).
37 Remove retaining plate A.
F-128 9803/8070-1 F-128

Service Manual - JCB 8250 Fastrac Transmision

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Section F

F-0 9803/8070-1 F-0

Contents Page No.

Contents Page No.

Type A continuously variable transmission for forward and

Low Range Speed Forward Speeds depend on tyre size

High Range Speed Forward Speeds from 0 to 67 km/h (42 mph)

Test Test Point bar lbf/in2

F-1 9803/8070-1 F-1

Type Crown wheel and pinion primary reduction with epicyclic

Type Crown wheel and pinion primary reduction with epicyclic

F-2 9803/8070-1 F-2

A Turbo-charged 6 cylinder engine which is resiliently

F-3 9803/8070-1 F-3

F-4 9803/8070-1 F-4

The CVT is a continuously variable transmission for

The CVT cartridge is flexibly mounted in the transmission

Note: In circumstances where the engine will run but it is

F-5 9803/8070-1 F-5

3 Incremental encoder which is a position sensor with

The engine speed is reduced when a load is applied.

Automatic maximum output control is always

Automatic maximum output control functions:

The electronics detect the set point engine speed

F-6 9803/8070-1 F-6

4V5 4V4 p=18 bar

23 (4Z1) Clutch master cylinder

Cooled transmission oil is supplied to the high

Note: The item numbers/letters in red are shown in

F-9 9803/8070-1 F-9

Note: Some pressure test points are remotely mounted on

F-10 9803/8070-1 F-10

Note: The item numbers/letters in red are shown in

F-11 9803/8070-1 F-11

Note: Some pressure test points are remotely mounted on

The transmission oil temperature is monitored by the

The servo-pump (1P1) generates the system pressure for

Contamination of the pressure filter is monitored by a

F-12 9803/8070-1 F-12

High Pressure Relief Valve, Forward/Reverse

1 The pressure is equal in both chambers if the clutch/

3 The pressure is relieved by the clutch and the turbo

2V6 p=0- 500bar

F-13 9803/8070-1 F-13

F-14 9803/8070-1 F-14

Engine at idle, Machine stopped

F-15 9803/8070-1 F-15

Planetary gear/power splitting

A Planet carrier (drive from engine)

F-16 9803/8070-1 F-16

99% Hydrostatic - 1% Mechanical

F-17 9803/8070-1 F-17

50% Hydrostatic - 50% Mechanical

F-18 9803/8070-1 F-18

0% Hydrostatic - 100% Mechanical, Machine Speed 67 km/h, Engine 1500 rev/min

F-19 9803/8070-1 F-19

F-20 9803/8070-1 F-20

Low Pressures Table 1.

F-21 9803/8070-1 F-21

Test the following pressures, as the appropriate range

Note: The pressure reading will be shown for only half a

See Technical Data for specified pressures. K Pressure

F-22 9803/8070-1 F-22

!MCAUTION 5 Repeat the above procedure but select reverse drive