EAGLE TUGS PARTS & SERVICE MANUAL. Vehicle Types: TT 4, TT 5, TT 6, & TT 8. Engine Type: Ford Gasoline 2.5L

Transcription

1 EAGLE TUGS PARTS & SERVICE MANUAL Vehicle Types: TT 4, TT 5, TT 6, & TT 8 Engine Type: Ford Gasoline 2.5L

2 INTRODUCTION From everyone at Eagle Industrial Truck Manufacturing, we would like to say Thank You for purchasing an Eagle TTseries tow tractor. We take a lot of pride in the quality of the products that we build, as well as our continued customer service. Our goal is to build a long term relationship with our customers. We want you, the customer, to be 100% satisfied with your Eagle experience. To us, this means that your Eagle TT series tractor is functionally superior to any other products you have used. This also means that your Eagle product is continually supported in a professional, timely manner. PURPOSE & USE OF THIS MANUAL This manual is designed as a reference guide to make the reader more familiar with the components of the Eagle TT 4, TT 5, TT 6, and TT 8 tow tractor models. This manual includes part numbers and descriptions to assist the reader in ordering component spare/service parts. The manual also outlines the Scheduled Maintenance Intervals recommended by Eagle in order to keep your vehicle running properly. In this manual you will also find the Eagle Standard Warranty on all of the TT series tow tractors. However, for more detailed information on the Eagle Warranty and procedure, as well as information pertaining to the safe operation of your Eagle product, please see the Eagle Operations Manual that was also included with your vehicle. TECHNICAL ASSISTANCE When addressing a repair procedure or operational problem, please remember that Eagle technical support is only a phone call away. Eagle technicians are available to assist you in vehicle diagnostics and recommended repair procedures. We encourage you to use this service to reduce machine down time and to gain a better understanding of proper repair procedures. ORDERING SPARE/SERVICE PARTS Eagle inventories most of the component parts found in its TT series tow tractors, and most spare/service parts can be shipped the same day the order is received. Parts orders need to be received at Eagle by 12:00 pm (Noon) EST in order for the parts to be shipped that same day. Parts ordered after 12:00 pm EST will most likely be shipped the following day. CONTACT INFORMATION Eagle Corporate Office Northline Rd Taylor, MI (800) Customer Service Parts & Service Technical Support customerservice@eagletugs.com parts@eagletugs.com support@eagletugs.com (734) (800) (734) (800) (734) (800)

3 TABLE OF CONTENTS INTRODUCTION... 2 PURPOSE & USE OF MANUAL... 2 TECHNICAL ASSISTANCE... 2 ORDERING SPARE/SERVICE PARTS... 2 CONTACT INFORMATION... 2 WARRANTY... 5 VEHICLE ID INFORMATION... 5 WARRANTY REGISTRATION... 6 STANDARD WARRANTY... 6 SCHEDULED MAINTENANCE... 7 TT 4, 5, 6, & 8 GASOLINE MAINTENANCE INTERVALS... 7 LUBRICATION CHART TT SERIES ALL WHEEL DRIVE... 8 LUBRICATION CHART TT SERIES REAR WHEEL DRIVE... 9 SERVICE PARTS ILLUSTRATIONS & DETAIL IDENTIFICATION KEY POWER TRAIN Engine Dress Engine To Transmission Stack Up Engine Dress Sensor Placement WITHOUT Shutdown Engine Dress Sensor & Water Tube Placement WITH Shutdown DRIVELINE Drive Shaft Assembly Front Drive Shaft Assembly Rear TRANSMISSION Cooling System Transmission Transaxle Mounting & Misc. Parts Transaxle Mounting & Misc. Parts Detail Transaxle Case Extension & Retainer Transaxle Case Extension & Retainer Detail COOLING SYSTEM Cooling System Ford 2.5L...23 AXLES Axle Assembly Front Non Drive (2WD) Axle Assembly Front Drive (4WD) Axle Assembly Rear Axle Assembly Breakdown Front Non Drive (2WD) Axle Assembly Breakdown Front Non Drive Detail Axle Assembly Breakdown Front Drive (4WD) Axle Assembly Breakdown Front Drive Detail Axle Assembly Breakdown Front Drive Detail Axle Assembly Breakdown Rear Drive Axle Assembly Breakdown Rear Drive Detail

4 BRAKES, WHEELS & TIRES Brake Caliper Assembly Rear Brake Caliper Assembly Rear Detail Brake System Hydraulic Brake System Hydraulic Detail Brake Actuator Assembly Brake Actuator Assembly Detail Parking Brake Actuator Assembly Parking Brake Actuator Assembly Detail Wheel & Tire Assembly Wheel & Tire Assembly Dual Rear Wheel Model STEERING SYSTEM Steering System Breakdown Steering System Breakdown Detail Hydraulic Actuation Braking System.46 AIR CLEANER, FUEL SYSTEM & EXHAUST Air Cleaner Sub Assembly Air Cleaner Assembly Ford 2.5L Air Cleaner Assembly Ford 2.5L Detail Fuel & EFI System Fuel & EFI System Detail EFI Control Ford 2.5L Exhaust System Ford 2.5L...53 OPETRATOR COMPARTMENT Transmission Control Accelerator Pedal Assembly Instrument Panel Instrument Panel Detail LIGHTS & ELECTRIAL Electrical Component Board...58 Headlight & Taillight Assembly Wiring Harness Wiring Diagram EFI 2.5L Wiring Diagram EFI 2.5L OTHER ASSEMBLIES Body Assembly Body Assembly Detail ENGINE DIAGNOSTICS ENGINE MALFUNCTION INDICATOR LIGHT WITH SHUTDOWN.65 ENGINE MALFUNCTION INDICATOR LIGHT WITHOUT SHUTDOWN..65 FORD POWER PRODUCTS SERVICE INFORMATION

5 WARRANTY VEHICLE ID INFORMATION This information can be found on the tractor s I.D. Plate located on the firewall next to the driver s seat. Additionally, there is a permanent serial number located on the rear bulkhead inside the engine compartment. MODEL SERIAL # MFG DATE ENGINE TYPE ENGINE SERIAL # FORD 2.5L DISTRIBUTOR # Gas Engine: EC42907; LPG Engine: EC

6 WARRANTY WARRANTY REGISTRATION Please fill out the engine warranty registration card that comes with your vehicle. This information is needed for completing warranty work on your engine if a problem occurs. See Vehicle ID Information on previous page. STANDARD WARRANTY Eagle Industrial Truck Manufacturing, LLC (EAGLE) warrants that EAGLE tow tractors will be free from defects in material and workmanship for a period of 12 months or 2,000 operating hours (whichever comes first), beginning at the date of delivery. The 12 month/2,000 hour Warranty covers everything except for the electrical and cooling systems, which are covered for 3 months or 500 hours (whichever comes first). Written notice of any claimed defect must be given to EAGLE within the warranty period and within thirty (30) days after such defect is discovered. Liability under this warranty is limited to either replacing or repairing, at EAGLEʹs election, any part or parts deemed defective after examination by EAGLE or an Authorized Service Representative. Any EAGLE tow tractor or any of its parts returned by the customer to EAGLE or an Authorized Service Representative via prepaid transportation, and which is found to be defective, will be repaired or replaced and returned to customer prepaid. On the other hand, should a part be found not defective, inspection and handling charges may be charged to the customer or Authorized Service Representative by EAGLE. This warranty does not extend to tires and batteries as these are warranted directly to the user by their respective manufacturer and not by EAGLE or an Authorized Service Representative. This warranty does not apply to any EAGLE tow tractor, or component parts that have been subjected to misuse, accident, or improper handling, maintenance or application; nor does it extend to the EAGLE tow tractor and/or parts which have been repaired or altered outside of EAGLEʹs plant or the facility of an Authorized Service Representative. This warranty does not apply to routine maintenance, ignition components, or wearable parts of the EAGLE tow tractor such as filters, seals, plugs, hoses, belts, brake pads, light bulbs, fuses or similar items. Moreover, this warranty does not extend beyond its original term for any EAGLE tow tractor or part replaced or repaired under warranty. If a warranty problem occurs with your engine, please contact an authorized engine distributor for assistance. (A list of Ford Power Products Service organizations can be found at the back of this manual) EXCEPT AS SET FORTH ABOVE, ALL WARRANTIES, CONDITIONS, REPRESENTATIONS, INDEMNITIES AND GUARANTEES, EXPRESS OR IMPLIED, WHETHER ARISING BY STATUTE, CUSTOM OF TRADE OR UNDER ORAL OR WRITTEN STATEMENTS MADE BY OR ON BEHALF OF EAGLE NEGOTIATIONS WITH THE CUSTOMER, DISTRIBUTOR, DEALER OR ANY REPRESENTATIVE, ARE HEREBY OVERWRITTEN AND EXCLUDED, AND NO LIABILITY SHALL ATTACH TO EAGLE, EITHER IN CONTRACT OR IN TORT, OR STRICT LIABILITY IN TORT, FOR ANY DAMAGE TO PROPERTY, LOSS OF PROFITS, DAMAGES, COSTS, CHARGES, LIABILITY OR EXPENSES, WHETHER DIRECT OR INDIRECT, CONSEQUENTIAL OR OTHERWISE, WHICH ARISE OUT OF OR IN CONNECTION WITH THE SALE OR USE OF ANY EAGLE TOW TRACTOR OR THE SUPPLY OF SERVICES. SUBJECT TO CHANGE WITHOUT NOTICE 6

7 SCHEDULED MAINTENANCE TT 4, 5, 6, & 8 GASOLINE MAINTENANCE INTERVALS Interval Check/Inspect Service Replace Part # Description Engine Oil Refill fluid levels as required Daily Power Steering Fluid Transmission Fluid Brake Fluid (Master Cylinder) N/A N/A All of the above, plus: Components that show wear Valve Cover Gaskets or appear damaged Engine Rubber Mountings Clean engine air cleaner Inlet & Exhaust Pipe to Manifold Throttle Controls Coolant Levels Every 50 All Hoses for deterioration Hours and/or chafing All Belt Drives for wear and proper tension Fuel System for leaks Electrical System for frayed wires and/or loose connections N/A N/A Steering arms bolts Re torque to 120 Ft lbs All of the above, plus: Components that show wear D9AZ6731A Oil Filter Every 100 Hours Battery Cables for Corrosion or appear damaged Change oil and replace oil filter Steering arms bolts Re torque to 120 Ft lbs All of the above, plus: Components that show wear P Air Cleaner Element 2ʺ Drum Brake Linings, Lines & or appear damaged P Air Cleaner Element 3ʺ Hoses Replace Air Cleaner Element Trans. Filter & Gasket Every 500 Replace Fuel Filter F8JL9A011AA Fuel Filter Hours Replace Transmission Fluid & Filter Rotate Tires Steering arms bolts Re torque to 120 Ft lbs All of the above Components that show wear Every 1000 or appear damaged Replace Hypoid Gear Lubricant Hours in Drive Axles N/A N/A Steering arm bolts Re torque to 120 Ft lbs All of the above Components that show wear RD52 Front Brake Pads Every 2000 Hours Steering arms bolts or appear damaged FR357 Rear Brake Shoes E4EE8620NA Alternator Belt A TT Headlight (Pre 12/04) A TT Headlight 1157 Tail Light Bulb A TT Accelerator Cable E2JL8A570AA Thermostat AA Thermostat Gasket Re torque to 120 Ft lbs N/A 7

8 LUBRICATION CHART TT SERIES ALL WHEEL DRIVE Item Identification Type Service Lubricant 1 Steering Linkage Lube EP Multipurpose Grease 2 Transmission Oil* Check Dextron III 3 Engine Oil Change OE/HDO (MIL-L-2104) 4 Drive Axles Check GO (MIL-L-2105) 5 Power Steering Pump Check Power Steering Fluid 6 Drive Shaft Lube EP Multipurpose Grease 7 Brake Master Cylinder Check Dot 3 8 Engine Coolant Check MIL-A (Ethylene Glycol) *Check when engine is at operating temperature 8

9 LUBRICATION CHART REAR WHEEL DRIVE Item Identification Type Service Lubricant 1 Steering Linkage Lube EP Multipurpose Grease 2 Transmission Oil* Check Dextron III 3 Engine Oil Change OE/HDO (MIL-L-2104) 4 Drive Axles Check GO (MIL-L-2105) 5 Power Steering Pump Check Power Steering Fluid 6 Drive Shaft Lube EP Multipurpose Grease 7 Brake Master Cylinder Check Dot 3 8 Engine Coolant Check MIL-A (Ethylene Glycol) *Check when engine is at operating temperature 9

10 SERVICE PARTS ILLUSTRATIONS & DETAIL IDENTIFICATION KEY The following abbreviations are used throughout the parts lists in this section. Abbreviation Meaning Purpose NL Not Listed Part required but not shown on diagram NPN No Part Number Parts shown and numbered, but not stocked and sold by Eagle. Typically used for bolts, clamps, etc AR As required 10

11 NOTES: 11

12 POWER TRAIN ENGINE DRESS ENGINE TO TRANSMISSION STACK UP 11 ENGINE DRESS ENGINE TO TRANSMISSION STACK UP DETAIL Item Part Number Qty Description 1 TMD27B00521 F2.5 1 ENGINE PLATE 2 B TT5G F2.5 1 TRANS PLATE 3 B TT5G F2.5 1 FLY WHEEL 4 B TT5G F2.5 1 FLEX HUB 5 B TT5TG F2.5 1 FLEX PLATE 6 TM27COO305 F2.5 1 FLEX PLATE WASHER 7 NPN 6 10X1X70 BOLTS 8 A TT5D TRANSAXLE DOWEL PINS 10 B TT5D TRANS MOUNTS 11 NPN 2 3/4ʺ 16X3.5 GR8 HCS BOLT 12 NPN 2 3/4ʺ WASHER 13 NPN 2 MOTOR MOUNT SPACER 14 A TT5D ISOLATOR 15 A TT5D LORD WASHER 16 NPN 2 3/4ʺ LOCK NUT 12

13 POWER TRAIN ENGINE DRESS SENSOR PLACEMENT WITHOUT SHUTDOWN ENGINE DRESS SENSOR PLACEMENT WITHOUT SHUTDOWN DETAIL Item Part Number Qty Description 1 F4TZ FORD COOLANT TEMP SENDER 2 A TT FAN SWITCH 3 A TT OIL PRESSURE SENDER 4 A TT COOLANT TEMP SENDER 5 NPN 1 BULK HOSE B NIPPLE X8X6 2 BUSHING X8 1 TEE W/ PIPE X8 1 TEE B C DEGREE NIPPLE 11 F09Z6031A 1 MOTOR MOUNT 12 A TT5D ISOLATOR 13 A TT5D LORD WASHER 14 NPN 2 BOLT 15 NPN 1 MOTOR MOUNT 13

14 POWER TRAIN ENGINE DRESS SENSOR & COOLANT TUBE PLACEMENT WITH SHUTDOWN ENGINE DRESS SENSOR & COOLANT TUBE PLACMENT WITH SHUTDOWN DETAIL Item Part Number Qty Description 1 E95Z9278B 1 FORD OIL PRESSURE SENDER 2 A TT OIL PRESSURE SENDER 3 H SHUTDOWN PRESSURE SWITCH 4 A COOLANT TEMP SWITCH O RING COOLANT TUBE SET 7 NPN 1 BULK HOSE 8 A TT COOLANT TEMP SENDER * Without shutdown option #4 is part number A TT and #8 is eliminated 14

15 DRIVELINE DRIVE SHAFT ASSEMBLY FRONT 7 DRIVE SHAFT ASSEMBLY FRONT DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A TT TRANSMISSION OUTPUT YOKE SHAFT FRONT 2 A TT CROSS BEARING FRONT D/S NEW STYLE 3 A TT DRIVE SHAFT SPRING 4 A TT DRIVE SHAFT 5 A TT END YOKE STRAP AND BOLT KIT 6 A TT CROSS BEARING FRONT D/S NEW STYLE END YOKE 15

16 DRIVELINE DRIVESHAFT ASSEMBLY REAR DRIVE SHAFT ASSEMBLY REAR DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A TT TRANSMISSION OUTPUT YOKE SHAFT REAR 2 A TT DRIVE SHAFT SPRING 3 A TT CROSS BEARING FRONT D/S NEW STYLE 4 AB TT DRIVE SHAFT 5 A TT END YOKE STRAP KIT 6 A TT CROSS BEARING REAR D/S NEW STYLE 16

17 TRANSMISSION COOLING SYSTEM TRANSMISSION COOLING SYSTEM TRANSMISSION DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT TRANSMISSION COOLER 2 A-TT ELECTRIC FAN 3 NPN LOCK NUT 4 NPN 4 1/4" WASHER 5 XX FAN MOUNTING BRACKETS 6 NPN 2 TRANS COOLER BRACKET 7 NPN BOLT 8 NPN 4 #6 HOSE CLAMP 17

18 TRANSMISSION TRANSAXLE MOUNTING & MISC. PARTS 18

19 TRANSMISSION TRANSAXLE MOUNTING & MISC. PARTS DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT5D TRANSAXLE (COMPLETE) 2 A-TN GROUND STRAP SWITCH-NEUTRAL STARTER & BACK UP LIGHT INDICATOR-TRANSAXLE FLUID DOWEL PIN-TRANSAXLE TO ENGINE ALIGNMENT TORQUE CONVERTER 7 A-TT TRANSAXLE SHIFT LEVER-MANUAL CONTROL * SCREW-HEX CAP-WITH WASHER M X * GASKET & FILTER MAINTENANCE PACKAGE * CALL EAGLE PARTS DEPT. FOR DETAILS 19

20 TRANSMISSION TRANSAXLE CASE EXTENTION & RETAINER 20

21 TRANSMISSION TRANSAXLE CASE EXTENTION & RETAINER DETAIL Item Part Number Qty Description SCREW-HEX CAP-W/WASHER M X PAN 3 NPN 1 CUP(NOT SOLD SEPARATELY) SPACER KIT RETAINER, OIL RETAINER, BEARING SCREW-HEX CAP-M8 X 1.25 X 23 7 NPN 6 SCREW-HEX CAP-WASHER HEAD M X 8 NPN 10 SCREW-HEX CAP M X COVER, TRANS. END RTV SEALANT SCREW-HEX CAP W/WASHER M X SEAL, MANUAL VALVE SHAFT PAN, TRANSAXLE OIL SCREW-HEX CAP W/WASHER M X SCREW-HEX CAP-W/WASHER M6-1 X CUP RETAINER O-RING OUTPUT HOUSING SCREW-HEX CAP-W/WASHER M X NPN 2 M8 HEX HEAD SCREW SEAL 19 NPN 1 BUSHING (SERVICED IN EXT.) 20 NPN 4 SCREW-HEX CAP WASHER HEAD M X O-RING SPEEDOMETER CABLE ADAPTOR 23 NPN 1 SCREW-FLAT HEAD HEX SOCKET M X 24 NPN 1 SCREW-HEX CAP-WASHER HEAD M6-1.0 X 25 A-TT5D DIFFERENTIAL-WELDED SPIDER GEAR 26 A-TT TRANSMISSION PLUG (2WD ONLY) 21

22 COOLING SYSTEM COOLING SYSYEM FORD 2.5L COOLING SYSTEM FORD 2.5L Item Part Number Qty Description 1 A TT DEGREE HOSE 2 A TT BOTTOM RADIATOR HOSE 3 A TT4F BOTTOM RADIATOR TUBE 4 A TT4F TOP RADIATOR TUBE 5 NPN 1 CONNECTOR TUBE 6 A TT4F RADIATOR 2.5L GAS 7 A TT FAN SHROUD 8 A TT COOLING FAN 9 NPN 1 CONNECTOR TUBE 10 A TT BOTTOM HOSE 11 NPN 1 CONNECTOR TUBE 12 A TT U BOLT 13 NPN 1 RESERVOIR BRACKET 14 A TT RESERVOIR FILL TANK 15 NPN 1 SEE PAGE # 14 FOR BREAKDOWN 16 NPN 1 SEE PAGE # 13 FOR BREAKDOWN 22

23 AXLES AXLE ASSEMBLY FRONT NON DRIVE TT4 TT6 2WD ONLY AXLE ASSEMBLY FRONT NON DRIVE DETAIL Item Part Number Qty Description 1 A TT AXLE ASSAY FRONT NON DRIVE 2 C TT STEERING ARM TT4 TT8/2AWD 3 A TT STUD STEERING ARM BUSHING 5 NPN 3 9/16 18 GR8 HEX NUT 6 NPN 4 SCREW HEX CAP 3/8 16X3.5 7 A TT NYLON WASHER 8 A TT LEAF SPRING 9 NPN 8 3/8 16 LOCK NUT 10 A TT U BOLT KIT 11 A TT * 2 MACHINED AXLE CLAMP PLATE* 12 NPN** 8 WASHER** 13 NPN** 4 NUT, LOCK 9/ NPN 2 3/8 FLAT WASHER * AXLE CLAMP MUST BE MODIFIED CALL EAGLE PARTS DEPARTMENT FOR DETAILS **INCLUDED IN #7 U BOLT KIT NOTE: Steering arm bolts must be re torqued to 120 Ft lbs. (# 5 in above drawing) after 50, 100, 250, 500, 1000 and 2000 hours. If not checked bolts could loosen causing the steering knuckle to break. 23

24 AXLES AXLE ASSEMBLY FRONT DRIVE (4WD) AXLE ASSEMBLY FRONT DRIVE DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A TT FRONT DRIVE AXLE ASSEMBLY 2 C TT STEERING ARM TT4 TT8/2 AWD 3 A TT STUD STEERING ARM 4 A TT KIT 5 NPN 4 3/8X16 LOCK NUT 6 A TT NYLON WASHER 7 NPN 4 SCREW HEX CAP 3/8 16X3.5 8 NPN 3 NUT 9/16 18 GR BUSHING 10 NPN* 8 NUT HIGH 9/16 18* 11 A TT MACHINED AXLE CLAMP PLATE 12 A TT LEAF SPRING 13 NPN* 8 WASHER * INCLUDED IN #4 U BOLT KIT NOTE: Steering arm bolts must be re torqued to 120 Ft lbs. (# 8 in above drawing) after 50, 100, 250, 500, 1000 and 2000 hours. If not checked bolts could loosen causing the steering knuckle to break. 24

25 AXLES AXLE ASSEMBLY REAR AXLE ASSEMBLY REAR DETAIL 1 A TT REAR AXLE ASSEMBLY 2 A TT LEAF SPRING 3 A TT U BOLT 4 A TT AXLE CLAMP PLATE 5 A TT WASHER 6 A TT NUT LEFT HAND BACKING PLATE RIGHT HAND BACKING PLATE 25

26 AXLES AXLE ASSEMBLY BREAKDOWN FRONT NON DRIVE (2WD) 26

27 AXLES AXLE ASSEMBLY BREAKDOWN FRONT NON DRIVE DETAIL Item Part Number Qty Description X 1 TUBE ASSEMBLY NUT SLOTTED PIN COTTER RING ADJUSTING SOCKET ASSEMBLY UPPER NUT LOCK SOCKET ASSEMBLY LOWER RING SNAP BOLT STOP NUT JAM X KIT STEERING KNUCKLE R/H X KIT STEERING KNUCKLE L/H NUT SLOTTED PIN COTTER TR115 16X 1 TIE ROD ASSEMBLY PLUG CAP SPINDLE WHEEL BEARING NUT LOCK SEAL LOCK X KIT INNER WHEEL BEARING HU103 2 HUB & ROTOR ASSEMBLY X KIT OUTER WHEEL BEARING X 2 SPINDLE NUT LK WASHER WHEEL BRG NUT NUT SPINDLE CAP HUB STUD STEERING KNUCKLE N/S 044WC CALIPER ASSEMBLY R/H N/S 044WC CALIPER ASSEMBLY L/H N/S 044WB BRACKET ASSEMBLY CALIPER L/H N/S 044WB BRACKET ASSEMBLY CALIPER R/H WHEEL STUDS 27

28 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE (4WD) 81 81a 28

29 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE DETAIL Item Part Number Qty Description 1 A TT COMPLETE AXLE ASSEMBLY X 1 GEAR & PINION ASSEMBLY SLINGER PINION OIL INNER X KIT INNER PINION BEARING X KIT SHIM PINION ADJUSTING BAFFLE PINION OIL X KIT SHIM PINION BEARING ADJUSTING KIT OUTER PINION BEARING SLINGER PINION OIL OUTER SEAL OIL X 1 END YOKE ASSEMBLY WASHER PINION NUT NUT PINION 3/ AR RTV SEALANT 15a GASKET PLUG PIPE SQ DRIVE PLUG COVER PLATE 19 N/A 2 CAP DIFFERENTIAL BEARING BOLT DIF BEARING CAP X KIT DIFFERENTIAL BEARING X KIT DIFFERENTIAL SHIM X 1 CASE DIFFERENTIAL ASSY CASE DIFFERENTIAL SCREW HEX PINION DIFFERENTIAL X 2 GEAR DIFFERENTIAL KIT (INCLUDES 15a AND 24 29) THRUST WASHER DIFFERENTIAL PINION THRUST WASHER DIFFERENTIAL GEAR SHAFT DIFFERENTIAL PIN ROLL VENT SEAL & GUIDE SHAFT NUT SLOTTED PIN COTTER RING ADJUSTING SOCKET ASSEMBLY UPPER NUT LOCK SOCKET ASSEMBLY LOWER RING SNAP BOLT STOP NUT LOCK X KIT STEERING KNUCKLE R/H X KIT STEERING KNUCKLE L/H NUT SLOTTED PIN COTTER TR115 16X 1 TIE ROD ASSEMBLY SHAFT & JOINT ASSEMBLY SLINGER 29

30 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE DETAIL Item Part Number Qty Description SEAL OIL SPACER BEARING NEEDLE NUT LOCK X 2 SPINDLE NUT LOCK RETAINING NUT NUT SPINDLE RING SNAP CAP HUB GEAR AXLE DRIVE SPRING PRESSURE PLATE SPRING RETAINING X KIT OUTER WHEEL BEARING HU103 2 HUB & ROTOR ASSEMBLY X KIT INNER WHEEL BEARING SEAL OIL KIT SPINDLE ASSEMBLY X KIT SPINDLE SEAL & BEARING SEAL OIL 78 RD52 1 SET BRAKE PAD SET CALIPER ASSY LEFT CALIPER ASSY RIGHT SET ANCHOR BOLTS STEERING KNUCKLE STUDS 81a NUT LOCK 30

31 NOTES: 31

32 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE 32

33 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE DETAIL Item Part Number Qty Description A TT COMPLETE AXLE ASSEMBLY X KIT DRIVE GEAR & PINION X KIT INNER PINION BEARING X KIT SHIM DRIVE PINION ADJUSTING BAFFLE PINION BEARING X KIT SHIM PINION BEARING ADJUSTING X KIT OUTER PINION BEARING SLINGER PINION BEARING SEAL PINION X 1 END YOKE ASSEMBLY WASHER PINION NUT NUT PINION COVER ASSEMBLY RTV SEALANT 15a GASKET PLUG PIPE SLOTTED SCREW FLANGE HD 18 N/A 1 CAP DIFFERENTIAL BEARING /2 13 x 2.25 GRD8 BOLT BEARING CAP X KIT BEARING X KIT SHIM DIFFERENTIAL BEARING X KIT CASE DIFFERENTIAL BOLT DRIVE GEAR 24 SEE KIT KIT PINION DIFFERENTIAL 25 SEE KIT KIT GEAR DIFFERENTIAL 26 SEE KIT KIT THUST WASHER PINION 27 SEE KIT KIT THRUST WASHER GEAR 28 SEE KIT KIT SHAFT DIFFERENTIAL LOCK DIFFERENTIAL BOLT BRAKE MANUFACTURING NUT BRAKE MANUFACTURING SEAL OIL X KIT INNER WHEEL BEARING KIT OUTER WHEEL BEARING HUB & DRUM ASSEMBLY STUD HUB NUT SPINDLE LOCK WASHER WHEEL BEARING SHAFT AXLE FLANGE LONG SHAFT AXLE FLANGE SHORT ADAPTER STUD NUT LOCK VENT 060WD100 1 BRAKE ASSEMBLY SHOE TYPE RIGHT 060WD101 1 BRAKE ASSEMBLY SHOE TYPE LEFT KIT X DIFFERENTIAL PARTS (STANDARD) INCLUDES 15, 21 24, 29 KIT DIFFERENTIAL PARTS (LIMITED SLIP) INCLUDES 15, 21, 23, 24, 26, 28, 29,

34 BRAKES DRUM BRAKE ASSEMBLY REAR 21 34

35 BRAKES DRUM BRAKE ASSEMBLY REAR DETAIL Item Part Number Qty Description 060WD101 1 BRAKE ASSEMBLY L/H 060WD100 1 BRAKE ASSEMBLY R/H BACKING PLATE L/H BACKING PLATE R/H 2 FR357 1 SET SHOE & LINING SET CYLINDER ASSEMBLY L/H CYLINDER ASSEMBLY R/H WHEEL CYLINDERS CONNECTING LINK 6 *SEE KIT BELOW 1 COVER 7 *SEE KIT BELOW 1 SPRING UPPER 8 *SEE KIT BELOW 1 SPRING LOWER 9 *SEE KIT BELOW 2 SPRING HOLD DOWN 10 *SEE KIT BELOW 1 PIN 11 *SEE KIT BELOW 1 SPRING TENSION 12 *SEE KIT BELOW 1 BRAKE ADJUSTING LINK 13 *SEE KIT BELOW 1 CABLE GUIDE 14 *SEE KIT BELOW 1 CABLE ASSEMBLY 15 *SEE KIT BELOW 2 SPRING HOLD DOWN PARKING BRAKE CAM L/H PARKING BRAKE CAM R/H PARKING BRAKE LEVER (LEFT) PARKING BRAKE LEVER (RIGHT) BRAKE ANCHOR BOLT 24 *SEE KIT BELOW 1 BRAKE ADJUSTING SOCKET L/H 25 *SEE KIT BELOW 1 BRAKE ADJUSTING SCREW L/H 26 *SEE KIT BELOW 1 BRAKE ADJUSTING SOCKET 27 *SEE KIT BELOW 1 WASHER FLAT KIT H2588 LEFT BRAKE ADJUSTING KIT INCLUDES PART 6,10,11,12,14,13,20,24,25,26,27 KIT H2589 RIGHT BRAKE ADJUSTING KIT INCLUDES PART 6,10,11,12,14,13,20,24,25,26,27 KIT H7146 BRAKE SPRING KIT INCLUDES PART 7,8,9,15 35

36 BRAKES BRAKE SYSTEM HYDRAULIC

37 BRAKES BRAKE SYSYEM HYDRAULIC DETAIL Item Part Number Qty Description 1 A TT MASTER CYLINDER 2 A TT BRAKE LINE MASTER CYLINDER 3 A TT BRAKE LIGHT SWITCH TEE 4 A TT BRAKE LINE REAR 5 A TT BRAKE HOSE CLIP 6 A TT BRAKE HOSE REAR 7 A TT BRAKE LINE 8 A TT CROSS TEE 9 A TT BRAKE LINE REAR RT 10 A TT BRAKE LINE LEFT REAR 11 A TT BRAKE LINE FRONT REAR 12 NPN 4 LINE CLAMP 13 NPN 4 NUT A TT CROSS TEE 15 A TT BRAKE LINE FRONT RIGHT 16 A TT CALIPER BRAKE LINE 17 A TT BRAKE LINE FRONT LEFT 18 A TT BANJO BOLT WASHER KIT 20 A TT BRAKE LIGHT SWITCH 21 A TT FITTING MASTER CYLINDER ADAPTER 22 A TT FITTING MASTER CYLINDER ADAPTER 37

38 BRAKES BRAKE ACTUATOR ASSEMBLY 38

39 BRAKES BRAKE ACTUATOR ASSEMBLY DETAIL Item Part Number Qty Description 1 NPN 4 ¼ 20 SET SCREW 2 NPN 2 ½ 20 NUT 3 C TT THAMSON NYLINER BEARING 4 C TT BELL CRANK 5 C TT BELL CRANK PIVOT SHAFT 6 A TT CLEVIS PIN 7 NPN 3 COTTER PIN 8 A TT CLEVIS 9 NPN 1 ½ 20 X 12 ADJUSTING ROD 10 C TT BRAKE PEDAL PIVOT SHAFT 11 C TT BRAKE PEDAL 12* NPN 1 BRAKE PEDAL PIVOT 13 NPN 2 BELL CRANK STANDOFF 14 A TT SHAFT COLLAR 3/4ʺ * Welded to truck 39

40 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY 40

41 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY DETAIL Item Part Number Qty Description 1 A TT HAND BRAKE 2 NPN 4 SCREW HEX CAP 5/16 18 X 1 3 NPN 4 WASHER FLAT 5/16 4 NPN 4 NUT LOCK 5/ B TT CABLE PRIMARY 6 A TT BAR EQUALIZER 7 NPN 3 CLEVIS PIN 8 NPN 3 COTTER PIN 9 A TT PARKING BRAKE CABLE LEFT REAR 10 A TT PARKING BRAKE CABLE RIGHT REAR 11 NPN 1 SCREW HEX CAP X 1 12 NPN 1 WASHER FLAT 1/4 13 NPN 1 NUT LOCK 1/ NPN 1 SCREW HEX CAP 1/4 28 X 1 15 NPN 1 CABLE CLAMP PLATE 16 NPN 1 CABLE CLAMP HANDLE 17 NPN 2 NUT LOCK 1/ NPN 2 CABLE CLAMP 41

42 WHEELS & TIRES WHEEL & TIRE ASSEMBLY WHEEL & TIRE ASSEMBLY DETAIL Item Part Number Qty Description 1 A TT TIRE A TT STANDARD RIM 3 A TT LUG NUT 1 A TT8/ TIRE 16ʺ 2 A TT RIM 16ʺ * AE OPT SNOW TIRE (OPTION) * All current models equipped with standard 16 tire & rim 42

43 WHEELS & TIRES WHEEL & TIRE ASSEMBLY DUAL REAR WHEEL MODELS WHEEL & TIRE ASSEMBLY DUAL REAR WHEEL MODEL DETAIL Item Part Number Qty Description 1 A TT8/ STANDARD TIRE 16ʺ 2 A TT8/ RIM FRONT 3 A TT8/ RIM REAR 4 A TT ADAPTOR LUG NUT 5 A TT8/ WHEEL LUG NUT 6 A TT8/ WHEEL ADAPTER 43

44 STEERING SYSTEM STEERING SYSTEM BREAKDOWN 44

45 STEERING SYSTEM STEERING SYSTEM BREAKDOWN DETAIL Item Part Number Qty Description 1 A TT STEERING BOX 2 NPN 4 SCREW HEX CAP 7/16 14 X 2 GR8 3 A TT PITTMAN ARM 4 NPN 1 WASHER LOCK 3/4 5 NPN 1 NUT LOW 3/ A TT DRAG LINK 7 NPN* 2 COTTER PIN 1/8 X 1 ½ 8 NPN* 2 NUT TIE ROD ½ 20 9 A TT UNIVERSAL COUPLER 10 A TT SHAFT COUPLING 11 A TT UNIVERSAL JOINT 12 NPN 2 LOCKING BOLT DOG POINT 3/ A TT GIBB KEY 14 A TT STEERING SHAFT 15 A TT BEARING 16 A TT /8ʺ U BOLT 3/8ʺ HD 17 NPN** 4 WASHER FLAT 5/16 18 NPN** 4 NUT LOCK 5/ A TT STEERING WHEEL 20 N/A 1 SCREW HEX CAP 3/8 24 X 1 21 A TT COVER PLATE 22 A TT TIE ROD END L/H 23 A TT TIE ROD END R/H 24 A TT STEERING TUBE 25 A TT SPACERS 26 A TT /4 16 NUT JAM L/H 27 A TT /4 16 NUT JAM R/H 28 A TT HIGH PRESSURE EXTENDER 29 A TT RETURN LINE EXTENDER * 7& 8 NOT SOLD SEPERATELY INCLUDED IN PART # 22 & 23 ** PARTS INCLUDED IN PART # 16 45

46 STEERING SYSTEM HYDRAULIC ACTUATION BRAKING SYSTEM HYDRAULIC ACTUATION BRAKING SYSTEM DETAIL Item Part Number Qty Description 1 FOTZ3A674A 1 POWER STEERING PUMP 2 A TN PUMP PRESSURE LINE 3 A TN PUMP PRESSURE LINE B CO DEGREE FITTINGS 5 A TT FILTER HEAD 6 A TT MICRON FILTER 7 NPN 1 3/8ʺ HOSE 350 WORKING PRESSURE 8 A TT Y FITTING 9 A TT PUMP PRESSURE LINE 10 A TT FITTING 11 A TT RETURN LINE EXTENDER 12 A TT5D ADAPTOR, FORD POWER STEERING 46

47 AIR CLEANER AIR CLEANER SUB ASSEMBLY 2 1 AIR CLEANER SUB ASSEMBLY DETAIL Item Part Number Qty Description 1 A TT A TT AIR CLEANER 2ʺ AIR CLEANER 3ʺ 2 P P AIR CLEANER ELEMENT 2ʺ AIR CLEANER ELEMENT 3ʺ 47

48 AIR CLEANER AIR CLEANER ASSEMBLY FORD 2.5L 48

49 AIR CLEANER AIR CLEANER ASSEMBLY FORD 2.5L DETAIL Item Part Number Qty Description 1 A TT AIR CLEANER ASSEMBLY 3ʺ A TT AIR CLEANER ASSEMBLY 2ʺ 2 A TT AIR CLEANER BRACKET 3 NPN 4 NUT LOCK 3/ NPN 4 WASHER FLAT 3/8 5 NPN 4 SCREW HEX CAP 3/8 16 X 1 GR.5 6 NPN 10 HOSE CLAMPS 7 A TT RAIN CAP 3ʺ A TT RAIN CAP 2ʺ 8 A TT DEGREE ELBOW NPN 1 BULK INTAKE TUBE 3ʺ 10 NPN 1 BULK INTAKE TUBE 29.5ʺ 11 NPN 1 BULK INTAKE TUBE 11.5ʺ 12 A TT INTAKE TUBE REDUCER 2 TO 2 1/4 13 NPN 1 90 DEGREE ELBOW

50 FUEL SYSTEM FUEL & EFI SYSTEM 50

51 FUEL SYSTEM FUEL & EFI SYSTEM DETAIL Item Part Number Qty Description 1 A TT FUEL TANK 2 A TT FUEL SENDING UNIT 3 A TT FUEL CAP 4 A TT DEGREE ELBOW FITTING 5 NPN 2 5/16 HIGH PRESSURE LINE 350PSI 6 NPN 14 #4 HOSE CLAMP 7 F8JL9A011AA 1 FILTER FUEL TANK 8 N CONNECTOR 9 E7UZ9C407A 1 PUMP & ISOLATOR ASSY 10 N CONNECTOR 11 NPN 2 5/16 HIGH PRESSURE LINE 350PSI 12 N806188S190 2 CONNECTOR ASSY 9.52XTUEXB.35 HOSE 13 N806207S190 1 CONNECTOR BODY 6.35HOSE X F8JL9P917AA 2 PRUSSURE REGULATOR & FILTER 15 N806207S190 1 CONNECTOR BODY 6.35HOSE X NPN 2 5/16 HIGH PRESSURE LINE 350PSI 17 NPN 14 #4 HOSE CLAMP 18 N806207S190 1 CONNECTOR BODY 6.35HOSE X A TT BULKHEAD FITTING 51

52 FUEL SYSTEM EFI CONTROL FORD 2.5L EFI CONTROL FORD 2.5L DETAIL Item Part Number Qty Description 1 F8JL12A650AD 1 PROCESSOR ASSY ENG ELEC CTRL 2 F8JL12A581AF 1 WIRE ASSY ENGINE CONTROL 3 F8JL10A979AA 1 LIGHT MALFUNCTION INDICATOR 4 F5729G444C 6 SENSOR ASSY EXH GAS OXY (HEATED) 5 F5AC9J467CA 2 INSERT 6 F8JL14N089AA* 3 RELAYS S220A 1 HOSE - 3/16ID X 22" LONG S760A 3 HOSE - VACUUM 7/32ID X 76" LONG S 1 TEE 10 F8JL9S428AB 1 MAP SENSOR - BLD# 3350-S 11 F6SZ12A697A 1 SENSOR ASSY-AIR CHANGE TEMP Nm 52

53 EXHAUST EXHAUST SYSTEM FORD 2.5L 8 8 EXHAUST SYSTEM DETAIL Item Part Number Qty Description 1 E3ZZ9450A 1 EXHAUST GASKET 2 A TT4F EXHAUST PIPE 3 XUIL5E212AB 1 FORD CATALYTIC CONVERTER 4 A TT MUFFLER CLAMPS 5 A TT MUFFLER 6 A TT DEGREE TAIL PIPE 7 AE OPT SPARK ARRESTER (OPTION) 8 A TT PIPE HANGER 53

54 OPERATOR COMPARTMENT TRANSMISSION CONTROL TRANSMISSION CONTROL DETAIL Item Part Number Qty Description 1 A TT TRANSMISSION SHIFT CONTROL 2 A TT TRANSMISSION SHIFT CABLE 3 A TT TRANSMISSION CABLE BRACKET ASSEMBLY 4 A TT U BOLT KIT 5 A TT BALL JOINT KIT 6 A TT TRANSMISSION LEVER 54

55 OPERATOR COMPARTMENT ACCELERATOR PEDAL ASSEMBLY ACCELERATOR PEDAL ASSEMBLY DETAIL Item Part Number Qty Description 1 F5TZ9F836A 1 FOOT PEDAL WITH TWO PLUGS 1A F8JL12B476AA 1 WIRE HARNESS WITH TWO PLUGS 2 NPN 1 ELECTRONIC FOOT PEDAL BRACKET 3 1C329F836BA 1 FOOT PEDAL WITH ONE PLUG 3A 2U1L12B476AA 1 WIRE HARNESS WITH ONE PLUG 55

56 OPERATOR COMPARTMENT INSTRUMENT PANEL 56

57 OPERATOR COMPARTMENT INSTRUMENT PANEL DETAIL Item Part Number Qty Description 1 C TT DASH PANEL (NO INSTRUMENTS) 2 A TT OIL PRESSURE GAUGE 3 A TT FUEL GAUGE 4 A TT VOLT AMP GAUGE 5 A TT TEMP GAUGE 6 A TT HOUR METER 7 A TT IGNITION SWITCH (KEYED OPTION) 7 A TT IGNITION SWITCH (KEYLESS OPTION) 8 A TT PLATE, MOUNTING IGNITION SWITCH 10 A TT HEAD LIGHT SWITCH 11 A TT HORN BUTTON 12 A TT HEATER FAN SWITCH 13 A TT TEMPERATURE CONTROL CABLE (OPTION) NS A TT WIRE HARNESS (DASH ONLY) NS A TT AMP CIRCUIT BREAKER 57

58 LIGHTS & ELECTRICAL ELECTRICAL COMPONENT BOARD ELECTRICAL COMPONENT BOARD DETAIL Item Part Number Qty Description 1 B TT MOUNTING BRACKET 2 A TT STARTER RELAY 3 A TT HORN RELAY 4 A TT FUSE BLOCK SPADE TYPE 5 A TT FUSE (25 AMP) 6 NPN 10 SELF DRILLING SCREWS 7 A TT RELAY 8 NPN 2 LOCK NUT

59 LIGHTS & ELECTRICAL HEADLIGHT & TAILLIGHT ASSEMBLY HEADLIGHT & TAILLIGHT ASSEMBLY DETAIL Item Part Number Qty Description 1 A TT HEADLIGHT 2 A TT TAILLIGHT 3 NPN 2 WASHER FLAT 1/2 4 NPN 6 WASHER FLAT 1/4 5 NPN 2 NUT 1/ NPN 6 NUT 1/ AE OPT HEADLIGHT WITH TURN SIGNAL (OPTION) 59

60 LIGHTS & ELECTRICAL WIRING HARNESS 60

61 LIGHTS & ELECTRICAL WIRING DIAGRAM EFI 2.5L 61

62 LIGHTS & ELECTRICAL WIRING DIAGRAM EFI 2.5L 62

63 OTHER ASSEMBLIES BODY ASSEMBLY 63

64 OTHER ASSEMBLY BODY ASSEMBLY DETAIL Item Part Number Qty Description 2 A TT SEAT 2 A TT *BENCH SEAT (ON TT /2 MODELS) 3 NPN 1 HOOD PROP 4 NPN 1 HOOD PROP ASSEMBLY 5 C TT HOOD LATCH 6 D TT FRONT GRILL 7 A TT HORN ASSEMBLY 8 A TT HEAT SHIELD 9 D TT GRILL GUARD/ACCESS DOOR LATCH FOR ACCESS DOOR 11 C TT HOOD 12** AE OPT STANDARD E HITCH * Option for TT 8/2 only ** Optional not shown 64

65 ENGINE DIAGNOSTICS The Ford fuel injected engines are equipped with a diagnostic tool that will tell the operator that there is a problem with the engine. The Ford system uses an engine malfunction indicator light (installed on the instrument panel) that blinks when there is a problem. The indicator light blinks in different sequences that tell you what kind of problem exists depending on the sequence. The steps below may be taken to verify what type of engine problem exists. Once the steps have been followed, and you have recorded a trouble code sequence, a Ford Power Products technician should be contacted to let you know what the problem is and what steps should be taken to fix the problem. (Please see the listing of Ford Power Products service organizations on the next page.) ENGINE MALFUNCTION INDICATOR LIGHT WITH SHUTDOWN The following steps should be followed if your vehicle is equipped with a Low Oil/High Temp. Shutdown System: 1. In the right side of the engine compartment, find the ORANGE wire 26I next to the starter relay. It will be plugged into a RED wire with a Green Tracer. 2. Unplug the ORANGE and RED/GREEN wires. 3. Use a jumper wire to jump the RED/GREEN wire to the POSITIVE post on the battery. This will bypass the shutdown system. CAUTION - DO NOT START ENGINE WITH BYPASS INSTALLED. 4. Remove Dash Cover (under instrument panel) 5. Find WHITE test wire labeled GROUND-TO TEST on the left-hand side. 6. Plug the WHITE wire into the BLUE clip on the BLACK ground wire. 7. Turn key to ON position. (Not Start ) 8. The malfunction indicator light on the dash will begin to flash a test sequence : (1) (1,2) (1,2,3) It will flash this sequence 3 TIMES. 9. After 3 times, it will then flash a trouble code sequence if there is a problem with the engine. If the system is operating normally, with no problems, then the program will just keep repeating the test sequence. ENGINE MALFUNCTION INDICATOR LIGHT WITHOUT SHUTDOWN 1. Remove Dash Cover (under instrument panel) 2. Find WHITE test wire labeled GROUND-TO TEST on the left-hand side. 3. Plug the WHITE wire into the BLUE clip on the BLACK ground wire. 4. Turn key to ON position. (Not Start ) 5. The malfunction indicator light on the dash will begin to flash a test sequence : (1) (1,2) (1,2,3) It will flash this sequence 3 TIMES. 6. After 3 times, it will then flash a trouble code sequence if there is a problem with the engine. If the system is operating normally, with no problems, then the program will just keep repeating the test sequence. 65

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70 FORD POWER PRODUCTS SERVICE INFORMATION 70

71 FORD POWER PRODUCTS SERVICE INFORMATION 71