Illustrated Parts Manual
Model
3606
P/N - 8990299
Revised May 25, 2007
May 25, 2007 - A - Revised Manual
EFFECTIVITY PAGE
8990299 3606 i
EFFECTIVITY PAGE
3606 8990299-ii
Table of Contents
Page Page
SECTION 1 – MAIN FRAME AND COVERS
Main Frame ............................................................... 1.1
Covers And Guards ................................................... 1.3
SECTION 2 – OPERATOR’S CAB AND CONTROLS
Open Cab - Outer Panels .......................................... 2.1
Open Cab - Inner Console & Dash Panel ................. 2.3
Operator’s Seat And Seat Belt .................................. 2.5
Operator’s Seat And Seat Belt
(Optional) ............................................................ 2.7
Mirrors ....................................................................... 2.9
Throttle Pedal Control
(Cummins) ........................................................ 2.11
Throttle Pedal Control
(Perkins)............................................................ 2.13
Service Brake Pedal Mounting ................................ 2.15
Joystick Mounting .................................................... 2.17
Steering Column, Steering Wheel & Shifter ............ 2.19
Cab Door
(Optional) .......................................................... 2.21
Closed Cab - Outer Panels
(Optional) .......................................................... 2.23
Closed Cab - Inner Console & Dash Panel
(Optional) .......................................................... 2.25
Cab Heater
(Optional) .......................................................... 2.27
Front Windshield Wiper
(Optional) .......................................................... 2.29
Skylight Windshield Wiper
(Optional) .......................................................... 2.31
Rear Window & Rear Windshield Wiper
(Optional) .......................................................... 2.33
Soft Cab Enclosure
(Optional) .......................................................... 2.35
Fenders
(Optional) .......................................................... 2.37
SECTION 3 – DRIVE TRAIN
Drive Shaft - Transfer Box To Front Axle .................. 3.1
Drive Shaft - Transfer Box To Rear Axle ................... 3.3
Drive Shaft - Transmission To Transfer Box ............. 3.5
Transfer Box Housing And Covers ............................ 3.7
Transfer Box Gears And Shafts ................................ 3.9
Axle Housing - Front Axle........................................ 3.11
Axle Housing - Rear Axle ........................................ 3.13
Steer Cylinder And Swivels - Front Axle ................. 3.15
Steer Cylinder And Swivels - Rear Axle .................. 3.17
Differential Assembly - Front Axle ........................... 3.19
Bevel Gear And Pinion Set - Front/Rear Axles ....... 3.21
Brake Assembly - Front Axle ................................... 3.23
Brake Assembly - Rear Axle ................................... 3.25
Reduction Gears - Front/Rear Axles ....................... 3.27
Wheel Hub Assembly - Front/Rear Axles ................3.29
Axle Shafts - Front/Rear Axles.................................3.31
Differential Assembly - Rear Axle ............................3.33
Transmission Case, Plate & Converter Housing
(4 Speed)...........................................................3.35
Torque Converter And Drive Plates
(4 Speed)...........................................................3.37
Charging Pump, Drive, Filter & Reverse Idler
(4 Speed)...........................................................3.39
Forward And Reverse Shaft Group
(4 Speed)...........................................................3.41
First And Second Shaft Group
(4 Speed)...........................................................3.43
High, Third And Output Shaft Group
(4 Speed)...........................................................3.45
Output Shaft Group
(4 Speed)...........................................................3.47
Electric Control Group
(4 Speed)...........................................................3.49
Wheels And Tires.....................................................3.51
Transmission & Transfer Box Mounting ...................3.53
SECTION 4 – POWER PLANT
Engine Mounting - Cummins
(S/N 9179 and Before).........................................4.1
Engine Mounting - Cummins
(S/N 9180 and After)............................................4.3
Radiator And Oil Cooler
(Cummins) ...........................................................4.5
Exhaust System
(Cummins) ...........................................................4.7
Air Cleaner
(Cummins) ...........................................................4.9
Fuel System
(Cummins) .........................................................4.11
Engine Mounting
(Perkins Natural & Turbo) ..................................4.13
Radiator And Oil Cooler
(Perkins Natural & Turbo) ..................................4.15
Exhaust System
(Perkins Natural & Turbo) ..................................4.17
Air Cleaner
(Perkins Natural & Turbo) ..................................4.19
Fuel System
(Perkins Natural & Turbo) ..................................4.21
Cold Start Kit
(Cummins) .........................................................4.23
SECTION 5 – HYDRAULIC CIRCUITS
Power Steering Circuit ...............................................5.1
Unloader Valve Circuit ...............................................5.3
Boom Raise/Lower & Extend/Retract Circuit .............5.5
Attachment Tilt And Slave Circuit ..............................5.7
3606 Origin 7/98
T of C 1
Page Page
Frame Tilt & Stabilizer Circuit
(S/N 9883 and Before) ........................................ 5.9
Frame Tilt & Stabilizer Circuit
(S/N 9884 and After) ......................................... 5.11
Service Brake & De-Clutch Circuit........................... 5.13
Valve Plate Assy. w/o Aux. Hydraulics .................... 5.15
Valve Plate Assy. w/ Aux. Hydraulics ...................... 5.17
Transmission Cooling Circuit
(Cummins) ........................................................ 5.19
Transmission Cooling Circuit
(Perkins)............................................................ 5.21
Auxiliary Hydraulic Circuit
(Optional) .......................................................... 5.23
Joystick Circuit......................................................... 5.25
SECTION 6 – HYDRAULIC COMPONENTS
Main Pump ................................................................ 6.1
Directional Control Valves ......................................... 6.3
Unloader Valve .......................................................... 6.5
Slave Cylinder ........................................................... 6.7
Frame Tilt/Stabilizer Cylinder .................................... 6.9
Attachment Tilt Cylinder .......................................... 6.11
Hoist Cylinder .......................................................... 6.13
Extend Cylinder ....................................................... 6.15
Swing Carriage Cylinder
(Optional) .......................................................... 6.17
Side Tilt Carriage Cylinder
(Optional) .......................................................... 6.19
Hydraulic Reservoir ................................................. 6.21
Main Control Valve
(Boom Raise/Lower & Extend/Retract Sections) .....
6.23
Main Control Valve
(Attachment Tilt & Frame Tilt Sections) ............ 6.25
SECTION 9 – BOOM AND ATTACHMENTS
Inner Boom................................................................ 9.1
Intermediate Boom .................................................... 9.3
Outer Boom............................................................... 9.5
Boom Extend Chain .................................................. 9.7
Boom Retract Chain .................................................. 9.9
Quick Attach............................................................ 9.11
48” Carriage ............................................................ 9.13
60” Carriage
(Optional) .......................................................... 9.15
72” Carriage
(Optional) .......................................................... 9.17
Swing Carriage
(Optional) .......................................................... 9.19
Side Tilt Carriage
(Optional) .......................................................... 9.21
12 Ft. Truss Boom
(Optional) .......................................................... 9.23
Utility Bucket
(Optional) .......................................................... 9.25
Sheet Material Handler
(Optional) .......................................................... 9.27
PART NUMBER INDEX
SECTION 7 – ELECTRICAL
Electrical System - Cab Harness
(S/N 8249 and Before) ........................................ 7.1
Electrical System - Cab Harness
(S/N 8250 and After) ........................................... 7.3
Electrical System - Engine Harness .......................... 7.5
Electrical System - Closed Cab ................................. 7.7
Lighting System
(Optional) ............................................................ 7.9
SECTION 8 – DECALS AND PAINT
Decals And Paint
(Early Production) ............................................. 1.11
Decals And Paint
(Current Production) ......................................... 1.13
T of C 2
3606 Origin 7/98
Table of Contents
Page Page
3606 Origin 7/98
T of C 3
SECTION 1 – MAIN FRAME AND COVERS
Hoist Cylinder
Orient Fracture In Bearing Race at
Clock Position Shown For Each
2
4
Boom Pivot
Frame Tilt Cylinder
3
Stabilizer Cylinder
Slave Cylinder
10
9
12
11
8
7
1
5
6
34
33
3
27
32
2
31
41
30
5
29
21
11
20
10
11
12
26
10
13
2
12
5
See
Kits
15
Torque
Item 23
to 680 lb/ft.
(922 Nm)
14
40
MAIN FRAME
Application
10
12
37
38
36
41
27
3
23
25
24
11
39
1
2
2
5
2
5
6
3
4
7
8
4
9
2
26
21
See
Kits
12
13
10
11
20
4
14
5
10
2
40
15
20
17
19
14
18
22
16
1.1
17
14
18
19
20
28
42
PH0940
Apply
Item 42
to
Item 40
43
it
K
PF0791
PS0041
3606 Rev 9/99
MAIN FRAME
Item No. Part Number Qty. Description
1 Call Factory 1 Frame, Main
2 8520013 8 Fitting, Lube, 1/8 Self Tapping
3 8310116 12 Nut, Hex Lock 1-8
4 8307210 12 Washer, Flat 1"
5 8050001 6 Bearing, Self Align 1-1/2" I.D.
6 8520021 1 Fitting, Lube, 90° 1/8 Self Tapping
7 7088341 4 Spacer
8 7127934 1 Counterweight
9 8310050 4 HHCS, 1-8 x 6" Gr.5
10 7130322 6 Pin, Cylinder Mount 1.5 Dia.
11 8303752 6 HHCS, 5/16-18 x 3-1/2"
12 8305626 6 Nut, Hex Lock 5/16-18
13 8310339 8 HHCS, 7/8-9 x 12"
14 8310060 16 Washer, Flat 7/8" Hardened
15 7129362 2 Anchor, Cylinder
16 8040253 1 Axle, Rear
17 7132592 2 Plate, Anchor
18 8305634 8 Nut, Hex Lock 7/8-9
19 8310295 8 HHCS, 3/4-10 x 5-1/2" Gr.8
20 8307703 16 Washer, Flat 3/4" Hardened
21 8310067 8 Nut, Hex Lock Elastic 3/4-10
22 7127214 1 Mount, Cab
23 8303538 8 HHCS, 1-8 x 3" Gr.8
24 5724302 AR Shim
25 8310066 4 Washer, Flat SAE 1"
26 7124471 2 Conduit, 1" I.D. x 12-1/2"
27 8310061 8 Washer, 1" Hardened
28 8040252 1 Axle, Front
29 5752022 1 Bumper
30 8307112 2 Washer, Flat 1/2"
31 8307007 2 Washer, Lock 1/2"
32 8303625 2 HHCS, 1/2-13 x 1-1/4"
33 7127394 1 Hydraulic Reservoir/Engine Mount
34 7125861 1 Conduit, 3/4" (60" Cut to Fit)
35 8305644 1 Nut, Hex Lock 1/2-13
36 7120662 1 Pin, Hoist Cylinder Mount 2" Dia.
37 8303782 1 HHCS, 1/2-13 x 4"
38 8065640 1 Bearing, Self Align 2" I.D.
39 8050002 2 Bearing, Self Align 2-1/2" I.D.
40 8303551 4 HHCS, M10-1,5 x 16mm
41 7124491 2 Conduit, 1" I.D. x 15-1/2"
42 8526049 AR Adhesive Sealant
KITS
43 7137694 1 Kit, Tie Down (S/N 8083 and Before)
3606 Rev 9/99
1.2
COVERS AND GUARDS
47
46
10
48
45
9
7
8
40
39
6
3
20
5
4
7
1
19
24
21
25
2
11
3
15
11
18
13
14
12
13
13
17
14
23
16
22
37
36
32
34
33
10
35
13
14
38
13
14
33
22
42
22
31
26
4
25
13
23
27
40
40
41
23
22
43
44
41
5
25
29
13
23
28
13
30
13
23
28
13
14
PS0061
1.3
3606 Rev 9/99
COVERS AND GUARDS
Item No. Part Number Qty. Description
1 7130814 1 Hood, Engine
2 7129922 1 Hinge, Hood - Rear
3 7125731 4 Moulding, Black 7" Long
4 8307110 6 Washer, Flat 3/8" Narrow
5 8303540 6 HHCS, 1/4-20 x 1"
6 7129912 1 Hinge, Hood - Front
7 7131782 2 Retainer Ring, Latch
8 6620002 1 Moulding, Black 16" Long
9 8342807 1 Latch w/Key (Includes Item 10)
10 8342808 AR Key
11 8702157 2 Spring, Clip
12 8340035 2 Ball Stud - 13mm
13 8307106 24 Washer, Flat 5/16"
14 8305626 10 Nut, Hex Lock Elastic 5/16-18
15 8702156 1 Spring, Gas
16 7130072 1 Support, Cover
17 8303739 2 HHCS, 5/16-18 x 1-1/4"
18 8302406 2 Pin, Cotter
19 8310334 2 Pin, Clevis 3/8" Dia.
20 7132844 1 Panel, Engine
21 8303679 4 HHCS, 3/8-16 x 1-3/4" Gr.5
22 8303670 14 HHCS, 5/16-18 x 1"
23 8307004 14 Washer, Lock 5/16"
24 7129663 1 Cover, Engine, Rear
25 8305906 10 Nut, Retainer 5/16-18
26 8305645 4 Nut, Hex Lock Elastic 3/8-16
27 7129653 1 Cover, Engine, Front
28 8303744 4 HHCS, 5/16-18 x 1/2"
29 7129612 1 Bracket, Cover - Front
30 7129622 1 Bracket, Cover - Rear
31 7131652 2 Striker, Rear Door
32 8702158 1 Spring, Gas
33 8340036 2 Ball Stud - 10mm
34 7130173 1 Cover, Rear
35 8342416 2 Latch, Adjustable Trigger
36 8307112 2 Washer, Flat 1/2" Heavy
37 8305644 2 Nut, Hex Lock Elastic 1/2-13
38 8303625 2 HHCS, 1/2-13 x 1-1/4"
39 8307109 4 Washer, Flat SAE Light 1/4"
40 8305624 8 Nut, Hex Lock Elastic 1/4-20
41 8307202 4 Washer, Flat 1/4"
42 8303114 2 HHCS, 1/4-20 x 2-1/4" Gr.5
43 7134132 2 Hook, Rubber
44 7134122 2 Bracket, Anchor
45 7134142 2 Bracket, Hook
46 8303836 4 Screw, Slotted Pan Hd. #10-24 x 5/8"
47 8307111 4 Washer, Flat #10
48 8310085 4 Nut, Hex Lock Elastic #10-24
3606 Rev 9/99
1.4
SECTION 2 – OPERATOR’S CAB AND CONTROLS
OPEN CAB - OUTER PANELS
1
4
3
5
2
25
24
6
7
8
9
4
5
6
8
9
7
13
12
7
8
11
10
6
6
15
14
16
5
4
5
17
19
4
6
18
2.1
20
21
23
22
Torque to
280 lb/ft.
(380 Nm)
20
6
5
4
S/N 8373 and Before
21
22
26
19
PF0780
PS0331
3606 Rev 9/99
OPEN CAB - OUTER PANELS
Item No. Part Number Qty. Description
1 7126534 1 Operator’s Protective Structure - ROPS/FOPS
2 7131412 1 Headliner
3 7130663 1 Panel, Cab Rear
4 8310301 8 BHCS, 5/16-18 x 1" (S/N 8373 and Before)
5 8310124 8 Washer, Flat Plastic 5/16" (S/N 8373 and Before)
6 8305906 13 Nut, Retaining 5/16-18
7 8303670 5 HHCS, 5/16-18 x 1"
8 8307004 5 Washer, Lock 5/16"
9 7057141 4 Washer, Rebound
10 7130653 1 Panel, Cab Rear LH
11 8307203 1 Washer, Flat 5/16"
12 8310067 2 Nut, Hex Lock Elastic 3/4-10
13 8303034 4 BHCS, 1/4-20 x 3/4"
14 8990122 1 Holder, Owner/Operator Manual
15 8307202 4 Washer, Flat 1/4"
16 8305624 4 Nut, Hex Lock Elastic 1/4-20
17 7131493 1 Mat, Floor
18 8310353 2 Screw, Self Drilling #12-14 x 1" (S/N 8373 and Before)
19 7130643 1 Panel, Cab Front LH (S/N 8373 and Before)
7134453 1 Panel, Cab Front LH (S/N 8374 and After)
20 8278026 4 Isolator, Cab
21 7129441 4 Washer, Rebound
22 8310375 4 HHCS, 3/4-10 x 3-3/4" Gr.8
23 8307010 2 Washer, Lock 3/4"
24 7130633 1 Panel, Cab Front
25 7137152 1 Kit, Mesh Plate - Right Side
26 8526042 AR Adhesive, 10 Oz Spray Can (For Item 17)
10 BHCS, 5/16-18 x 1" (S/N 8374 and After)
10 Washer, Flat Plastic 5/16" (S/N 8374 and After)
(Includes Urethane & Installation Instructions)
3606 Rev 9/99
2.2
24
OPEN CAB - INNER CONSOLE & DASH PANEL
17
2
23
16
13
16
17
15
16
17
16
15
13
16
17
10
9
8
6
7
Torque to
6-8 lb/ft
(8-11 Nm)
1
2
11
6
5
21
13
2
3
13
22
14
16
20
16
13
17
19
2
18
17
16
15
4
2
2
2.3
12
14
15
PS0701
3606 Rev 9/99
OPEN CAB - INNER CONSOLE & DASH PANEL
Item No. Part Number Qty. Description
1 7130724 1 Dash, Front
2 8305906 10 Nut, Retaining 5/16-18
3 7130773 1 Cover, Lower Dash
4 8310353 3 Screw, Self Drilling #12-14 x 1"
5 8310016 2 HHCS, Slotted #10-24 x 1"
6 8310402 4 Spacer
7 8310360 4 Washer, Fender
8 8310085 2 Nut, Hex Lock Elastic #10-24
9 8580421 4 Nut, Well #10-32 x 1/2" Long
10 8310358 4 BHCS, #10-32 x 3/4"
11 7131003 1 Holder, Load Chart
12 7130744 1 Support, Console
13 7057141 7 Washer, Rebound
14 8305626 2 Nut, Hex Lock Elastic 5/16-18
15 8307203 5 Washer, Flat 5/16"
16 8307004 10 Washer, Lock 5/16"
17 8303739 9 HHCS, 5/16-18 x 1-1/4"
18 7130862 1 Armrest
19 7130734 1 Tool Bin, Rear
20 8310009 1 HHCS, 5/16-18 x 2"
21 8630010 1 Ring, Retaining
22 8307206 1 Washer, Flat 1/2"
23 7124531 1 Conduit, 1/4 x 5" Long
24 7132751 1 Conduit, 1/4 x 9-1/2" Long
3606 Rev 9/99
2.4
OPERATOR’S SEAT AND SEAT BELT
1
2
14
9
12
3
4
5
6
7
8
24
11
18
19
10
15
17
18
15
11
16
22
9
10
12
13
23
Torque to
20 lb/ft
(27 Nm)
PF0791
2.5
PF0791
21
20
it
25
K
18
19
Items 20 thru 23 Not
Required On Early
it
K
Production Cabs With A
Threaded Hole For
Tether Mounting
PS0120
3606 Rev 3/02
OPERATOR’S SEAT AND SEAT BELT
Item No. Part Number Qty. Description
1 8864053 1 Seat
2 8036009 1 Boot, 60/76mm (Not Shown)
3 8036010 1 Adjuster, 6" (Not Shown)
4 8036011 1 Damper (Not Shown)
5 8036013 4 Rollers, Up Stop Bumper/Down Stop Bumper- 7/16" Dia.(Not Shown)
6 8036014 1 Springs and Cable (Not Shown)
7 8036015 1 Hanger Knob Tension Shaft (Not Shown)
8 8036017 1 Cushion/Pan Assembly Kit (Not Shown)
9 7130412 2 Tether
10 7096491 2 Spacer
11 8864057 1 Seat Belt Assembly - 2" Retractable (Includes Items 12 thru 15)
12 NSS 2 Washer
13 NSS 1 Hex Hd Capscrew
14 NSS 1 Hex Hd Capscrew
15 NSS 2 Nut, Hex
16 7121543 1 Support, Seat
17 8303670 4 HHCS, 5/16-18 x 1" Gr. 5
18 8307106 12 Washer, Flat 5/16" Narrow
19 8305626 8 Nut, Hex Lock Elastic 5/16-18
20 8305404 2 Nut, Hex Jam 3/8-16
21 8307204 2 Washer, Flat 3/8"
22 7057141 2 Washer, Rebound
23 8305645 2 Nut, Hex Lock Elastic 3/8-16
24 8864058 1 Seat Belt Assembly - 3" Retractable (Includes mounting hardware)
25 8864019 1 Seat Belt Assembly - 3" Non-Retractable
3606 Rev 3/02
2.6
OPERATOR’S SEAT AND SEAT BELT
(Optional)
2
1
6
7
4
3
5
5
2
3
4
7
8
6
9
14
Torque to
20 lb/ft
11
12
13
(27 Nm)
PF0791
2.7
15
it
K
PF0791
16
9
10
Items 11 thru 14 Not
Required On Early
Production Cabs With A
Threaded Hole For
Tether Mounting
it
K
PS0310
3606 Rev 9/99
OPERATOR’S SEAT AND SEAT BELT
(Optional)
Item No. Part Number Qty. Description
1 8864055 1 Seat, Deluxe Cloth with Supension
2 7130412 2 Tether
3 7096491 2 Spacer
4 8864060 1 Seat Belt Assembly - 2" Retractable (Includes Items 5 thru 7)
5NSS2Nut, Hex
6 NSS 2 Hex Hd Capscrew
7 NSS 2 Washer, Flat
8 8303670 4 HHCS, 5/16-18 x 1" Gr. 5
9 8307106 8 Washer, Flat 5/16" Narrow
10 8305626 4 Nut, Hex Lock Elastic 5/16-18
11 8305404 2 Nut, Hex Jam 3/8-16
12 8307204 2 Washer, Flat 3/8"
13 7057141 2 Washer, Rebound
14 8305645 2 Nut, Hex Lock Elastic 3/8-16
15 8864058 1 Seat Belt Assembly - 3" Retractable (Includes mounting hardware)
16 8864019 1 Seat Belt Assembly - 3" Non-Retractable
8864056 1 Seat, Deluxe Vinyl with Supension
3606 Rev 9/99
2.8
MIRRORS
1
3
4
5
2
12
9
11
10
8
4
7
3
14
4
13
4
15
3
4
6
2.9
CLOSED CAB ONLY
PS0321
3606 Rev 5/99
MIRRORS
Item No. Part Number Qty. Description
1 8866514 1 Mirror Head, Convex
2 8866515 1 Arm Assembly, Mirror
3 8303548 2 HHCS, M6-1 x 19mm
4 8307024 A/R Washer, Lock M6 (Qty 2 for Open Cab, Qty 3 for Closed Cab)
5 8307109 2 Washer, Flat SAE 1/4" Light
6 8866529 1 Mirror, Rear View
7 8866530 1 Arm Assembly, Mirror
8 8303799 2 HHCS, M6-1 x 14mm
9 7136742 1 Kit, RH Mirror - Optional (Includes Item 10, 11 & 12)
10 8303836 2 Screw, Slotted Round Hd. #10-24 x 5/8"
11 8307003 2 Washer, Lock #10
12 8866516 1 Mirror Assembly, Rear View
13 7138366 1 Bracket, Mirror (Closed Cab Only)
14 8303799 1 HHCS, M6-1 x 14mm (Closed Cab Only)
15 8305047 1 Nut, Hex M6-1 (Closed Cab Only)
3606 Rev 5/99
2.10
THROTTLE PEDAL CONTROL
(Cummins)
3
4
1
5
8
6
20
10
9
11
12
2
18
19
6
15
13
14
16
17
PS0430
7
2.11
3606 Origin 7/98
THROTTLE PEDAL CONTROL
(Cummins)
Item No. Part Number Qty. Description
1 8162003 1 Pedal, Throttle (Includes Item 2)
2 8033178 1 Bellows, Throttle Pedal
3 8303615 3 HHCS, 1/4-20 x 1-1/4"
4 8307002 3 Washer, Lock 1/4"
5 8307109 4 Washer, Flat SAE 1/4"
6 8305402 2 Nut, Hex Jam 1/4-28 NF
7 8700116 1 Spring, Extension
8 8160073 1 Cable, Throttle
9 8303837 2 Screw, Slotted Pan Hd. #10-24 x 3/4"
10 8160610 1 Clamp, Cable
11 8303799 2 HHCS, M6 x 14mm
12 8307024 2 Washer, Lock M6
13 8340034 1 Rod End 1/4-28 Thd.
14 7127091 1 Extension, Throttle Lever
15 8305650 1 Nut, Hex Lock Elastic 1/4-28 NF
16 8303790 2 HHCS, M12x1.75 x 30mm PC 8,8
17 8307025 2 Washer, Lock M12
18 7127102 1 Bracket, Throttle Cable
19 8305002 2 Nut, Hex #10-24
20 8307003 2 Washer, Lock #10
3606 Origin 7/98
2.12
THROTTLE PEDAL CONTROL
(Perkins)
3
4
1
2
5
6
7
8
9
12
14
13
Throttle Lever For
Reference Only
11
10
6
15
5
16
PS0470
2.13
3606 Rev 5/99
THROTTLE PEDAL CONTROL
(Perkins)
Item No. Part Number Qty. Description
1 8162003 1 Pedal, Throttle (Includes Item 2)
2 8033178 1 Bellows, Throttle Pedal
3 8303615 3 HHCS, 1/4-20 x 1-1/4"
4 8307002 3 Washer, Lock 1/4"
5 8307109 5 Washer, Flat SAE 1/4 Narrow
6 8305402 2 Nut, Hex Jam 1/4-28 NF
7 8700116 1 Spring, Extension
8 8160073 1 Cable, Throttle
9 7128252 1 Bracket, Throttle
10 8303837 2 Screw, Slotted Pan Hd. #10-24 x 3/4"
11 8162213 2 Shim
12 8160610 1 Clamp, Cable
13 8307003 2 Washer, Lock #10
14 8305002 2 Nut, Hex #10-24
15 8340034 1 Rod End 1/4-28 Thd.
16 8305650 1 Nut, Hex Lock Elastic 1/4-28 NF
3606 Rev 5/99
2.14
SERVICE BRAKE PEDAL MOUNTING
See “Directional
Control Valves”
1
8
7
6
5
4
2
3
PS0530
2.15
3606 Rev 5/99
SERVICE BRAKE PEDAL MOUNTING
Item No. Part Number Qty. Description
1 7128403 1 Pedal, Service Brake
2 8305644 2 Nut, Hex Lock Elastic 1/2-13
3 8307206 2 Washer, Flat 1/2"
4 7129521 2 Pivot, Brake Pedal
5 8303755 4 HHCS, M10-1,5 x 30mm
6 8307023 4 Washer, Lock M10
7 8303658 2 HHCS, 1/2-13 x 2"
8 8307112 2 Washer, Flat 1/2" Narrow
3606 Rev 5/99
2.16
JOYSTICK MOUNTING
2
1
3
4
5
Torque to 8 lb/ft
(11 Nm) 3 Places
Front Dash for
Reference Only
PS0730
2.17
3606 Rev 1/00
JOYSTICK MOUNTING
Item No. Part Number Qty. Description
1 7133942 1 Joystick Assembly (Includes Item 2 and 3)
2 7133932 1 Handle Assembly
3 8035777 1 Rubber Boot
4 8303705 3 Flange Hd. Capscrew 1/4-20 x 3/4"
5 8307002 3 Washer, Lock 1/4"
3606 Rev 1/00
2.18
STEERING COLUMN, STEERING WHEEL & SHIFTER
1
2
17
18
16
11
10
12
17
15
14
13
9
8
Power Steering Valve
See “Directional Control
Valves”
3
4
6
7
5
2.19
PS0541
3606 Rev 3/02
STEERING COLUMN, STEERING WHEEL & SHIFTER
Item No. Part Number Qty. Description
1 8720017 1 Cover, Horn Button
2 8310315 1 Nut, Thin M18-1,5
3 8720016 1 Wheel, Steering
4 8310350 2 Screw, Hex Socket Hd. #10-32 x 1-1/2"
5 7130763 1 Cover, Steering Column, Bottom
6 7121523 1 Steering Column (Includes Item 7 thru 9)
7 8035803 1 Gas Spring - Steering Column
8 8035804 1 Boot, Tilt Lever
9 8580118 1 Knob, Tilt Steering
10 8307003 2 Washer, Lock #10
11 8305003 2 Nut, Hex #10-32
12 8223029 1 Switch, Transmission Shift Control
13 7131961 2 Spacer, Transmission Shifter
14 8307005 4 Washer, Lock 3/8"
15 8304672 4 Screw, Hex Socket Hd. 3/8-16 x 1"
16 8310359 4 Nut, “J” #10-24
17 8310372 4 Screw, Button Hd. #10-24 x 5/8"
18 7130753 1 Cover, Steering Column, Top
3606 Rev 3/02
2.20
CAB DOOR
(Optional)
2
20
1
14
15
16
10
13
40
41
37
42
23
9
12
7
32
12
35
19
32
5
22
32
31
5
17
5
18
30
28
31
29
34
39
31
43
3
4
10
27
36
33
24
6
8
8
8
25
11
26
8
21
38
PS0860
2.21
3606 Origin 7/99
CAB DOOR
(Optional)
Item No. Part Number Qty. Description
1 8035470 1 Door Assembly - Closed Cab (Includes Items 2-40)
2 8033072 1 Seal, Bulb 90°, 192" Long
3 8035436 1 Grommet, 3/4 OD x 1/2 ID
4 8035437 1 Screw, 1/4-20 x 3/4"
5 8033058 6 Screw, 1/4-20 x 3/4" Whizlock
6 8035438 1 Handle, Door - Inside
7 8035439 1 Latch, Door
8 8035440 10 Screw, Pan Hd #10-16 x 3/4"
9 8035441 1 Latch, Paddle - RH Black
10 8035442 1 Strap, Door Restraint
11 8035443 1 Door Seal w/Flap - 70"
12 8035444 2 Retainer, Push On - 3/16" Rod
13 8035445 1 Bolt, Hex 5/16-18 x 1" Gr 8
14 8034798 1 Nut, Hex 5/16-18 Gr 8 Yellow
15 8034799 1 Washer, Lock .315 x .575 x .085 Thick
16 8035435 1 Washer, Flat .313 x .750 x .060 Thick
17 8035446 1 Door Hinge, Top
18 8035447 1 Door Hinge, Center
19 8035448 1 Door Hinge, Bottom
20 8035449 1 Window Assembly-LH Door
21 8035450 1 Door Panel, Interior
22 8035451 1 Door Panel, Exterior
23 8035452 1 Release Rod, Exterior
24 8035453 1 Release Rod, Interior
25 8035454 1 Pocket, Interior Door Panel
26 8035455 1 Switch, Electric Window
27 8035456 1 Wire Harness, LH Door
28 8035457 1 Hinge, Top
29 8035458 1 Hinge, Center
30 8035459 1 Hinge, Bottom
31 8035460 3 Washer, Hinge Brass
32 8035461 6 Screw, Flat Hd Hex Drive 1/4-20 x 1-1/4"
33 8035462 1 Retainer, Clip On
34 8035463 4 Screw, Truss Hex Drive 1/4-20 x 5/8"
35 8035464 4 U-Nut, 1/4-20
36 8037206 1 Seal, “D”Type Bulb .216 x .354 x 54"
37 8035466 4 Screw, Flat Head 1/4-20 x 3/4"
38 8035467 1 Grommet, 3/8 ID x 5/8 OD
39 8035468 4 Washer, Flat .281 x 1.05 x .065 Thick
40 8342808 1 Key Set, LL22
41 8035471 1 Glass, Door - Closed Cab
42 8035472 1 Channel, Glass
43 8035473 1 Regulator, Electric Window 12V
3606 Rev 3/02
2.22
CLOSED CAB - OUTER PANELS
(Optional)
24
33
25
23
13
31
4
5
31
27
See Rear
2
14
Window &
Rear Wind-
shield Wiper
3
1
6
7
7
8
9
8
9
12
7
26
10
8
11
6
6
4
5
28
6
16
4
5
5
18
15
30
29
32
PF0780
PF0810
34
4
PF0810
19
20
22
21
6
17
19
6
18
5
4
S/N 8373 and Before
20
21
Torque to
280 lb/ft.
(380 Nm)
PS0870
2.23
3606 Origin 9/00
CLOSED CAB - OUTER PANELS
(Optional)
Item No. Part Number Qty. Description
1 NSS 1 Operator’s Protective Structure - ROPS/FOPS
2 7131412 1 Headliner
3 7130663 1 Panel, Cab Rear
4 8310301 8 BHCS, 5/16-18 x 1" (S/N 8373 and Before)
5 8310124 8 Washer, Flat Plastic 5/16" (S/N 8373 and Before)
6 8305906 13 Nut, Retaining 5/16-18
7 8303670 5 HHCS, 5/16-18 x 1"
8 8307004 5 Washer, Lock 5/16"
9 7057141 4 Washer, Rebound
10 7130653 1 Panel, Cab Rear LH
11 8307203 1 Washer, Flat 5/16"
12 8310067 2 Nut, Hex Lock Elastic 3/4-10
13 7136342 1 Windshield, Front (Includes Glass, Setting Blocks & Urethane Seal)
14 8035474 1 Glass, Rear
8035606 1 Rear Window Assy. (Includes Glass, Hinges, Brackets, Seal and Hardware)
15 8035524 1 Window, Front LH (Includes Glass, Frame & Urethane Seal)
16 7138234 1 Mat, Floor
17 8310353 2 Screw, Self Drilling #12-14 x 1" (S/N 8373 and Before)
18 7130643 1 Panel, Cab Front LH (S/N 8373 and Before)
7134453 1 Panel, Cab Front LH (S/N 8374 and After)
19 8278026 4 Isolator, Cab
20 7129441 4 Washer, Rebound
21 8310375 4 HHCS, 3/4-10 x 3-3/4" Gr.8
22 8307010 2 Washer, Lock 3/4"
23 7137733 1 Panel, Cab Front
24 8035294 1 Window, Right Side
25 8035721 3 Block, Setting
26 8035525 1 Window, Rear LH (Includes Glass, Frame & Urethane Seal)
27 8035527 1 Window, Skylight
28 8035526 2 Bolt, Truss 5/16-18 x 2" Black
29 8035528 1 Striker Assembly
30 8035529 1 Striker Plate, Blind Nut
31 8035490 24 Block, Setting
32 8526042 AR Adhesive, 10 Oz Spray Can (For Item 17)
33 8035523 1 Urethane Seal, Tube - Black
34 8035723 1 Caulk, Tube - Orange
10 BHCS, 5/16-18 x 1" (S/N 8374 and After)
10 Washer, Flat Plastic 5/16" (S/N 8374 and After)
3606 Origin 9/00
2.24
CLOSED CAB - INNER CONSOLE & DASH PANEL
(Optional)
7
13
Steering Weldment
Inside Cab - Ref.
30
16
2
3
30
24
10
9
11
Holder Is
Shown
Rotated
For
Clarity
18
21
30
2
1
8
6
Torque to
6-8 lb/ft
(8-11 Nm)
40
7
6
5
13
16
17
20
16
13
22
30
42
26
30
30
2
35
19
4
39
37
39
2
13
30
39
30
31
16
36
17
32
14
15
13
12
38
33
29
41
34
25
27
26
23
39
43
28
2
2
PS0880
2.25
3606 Origin 9/99
CLOSED CAB - INNER CONSOLE & DASH PANEL
(Optional)
Item No. Part Number Qty. Description
1 7137654 1 Dash, Front
2 8305906 10 Nut, Retaining 5/16-18
3 7130773 1 Cover, Lower Dash
4 8310353 3 Screw, Self Drilling #12-14 x 1"
5 8310016 2 HHCS, Slotted #10-24 x 1"
6 8310402 4 Spacer
7 8310360 4 Washer, Fender
8 8310085 2 Nut, Hex Lock Elastic #10-24
9 8580421 4 Nut, Well #10-32
10 8310358 4 BHCS, #10-32 x 3/4"
11 7131003 1 Holder, Load Chart
12 7137364 1 Support, Console
13 7057141 7 Washer, Rebound
14 8305626 2 Nut, Hex Lock Elastic 5/16-18
15 8307203 5 Washer, Flat 5/16"
16 8307004 10 Washer, Lock 5/16"
17 8303739 9 HHCS, 5/16-18 x 1-1/4"
18 7130862 1 Armrest
19 7137664 1 Tool Bin, Rear
20 8310009 1 HHCS, 5/16-18 x 2"
21 8630010 1 Ring, Retaining
22 8307206 1 Washer, Flat 1/2"
23 7124531 1 Conduit, 1/4 x 5" Long
24 7132751 1 Conduit, 1/4 x 9-1/2" Long
25 8990147 1 Holder, Owner/Operator Manual
26 6620971 3 Clip, Retainer
27 8303540 2 HHCS, 1/4-20 x 1" Gr5
28 8307002 2 Washer, Lock
29 8035397 24 Screw, Self Tapping #8-32 x 1/2"
30 8035398 4 Louver, Ball
31 8035399 1 Hose, Flex 2-1/2" Dia. Rear RH Vent - 33" Long
32 8035400 1 Hose, Flex 2-1/2" Dia. Rear LH Vent - 37" Long
33 8035401 1 Weldment, Vent Manifold
34 8035402 1 Louver, Round
35 8035403 1 Hose, Flex 2-1/2" Dia. Center Vent - 30" Long
36 8035404 1 Hose, Flex 2-1/2" Dia. Front RH Vent - 18" Long
37 8035405 1 Hose, Flex 2-1/2" Dia. Front LH Vent - 40" Long
38 8033032 2 Sponge Rubber, Adhesive Backed 80" Long
39 8035406 10 Tie Sprap, Nylon 3/16 Wide x 12" Long
40 8035407 1 Panel, Heater Control
41 8035599 1 Foam Strip - PSA 1/4 x 1/2 x 100"
42 7138275 1 Neoprene Strip 1/2 x 1 x 28"
43 8307109 2 Washer, Flat
8035521 1 Panel, Heater & A/C Control
3606 Origin 9/99
2.26
CAB HEATER
(Optional)
26
3
25
Seat
Deck- Ref.
12
13
36
27
24
37
19
14
7
15
23
Apply
Thread-
locker
6
5
4
1911
3
17
18
4
5
8
6
10
33
21
22
32
20
14
4
5
6
16
PS0890
32
Outboard Side of Engine
35
32
32
29
32
2.27
38
39
PH0940
2
35 32
29
Inboard Side of Engine
31
34
32
30
28
PERKINS ENGINE CUMMINS ENGINE
31 34
32
3606 Origin 9/99
CAB HEATER
(Optional)
Item No. Part Number Qty. Description
1 8035412 1 Plenum
2 8035413 1 Valve, Heater - Motorized w/Module & Harness
3 8035414 11 Screw, 1/4-20 x 1"
4 8035415 13 Washer, Flat .281 x .625
5 8035416 13 Washer, Lock .254 x .480 - Black
6 8035417 13 Nut, Hex 1/4-20 - Black
7 8035418 1 Angle, RH Side
8 8035419 1 Angle, LH Side
9 8035420 4 Bolt, Carriage 1/4-20 x 1"
10 8035421 4 Screw, M6 x 12 - Whizlock
11 8035422 4 Rivet, Pop 3/16 x 1/2"
12 8035423 2 Angle, Filter Clamp
13 8035424 2 Rivnut, 5/16 Hex
14 8035425 1 Latch, LH - Filter Hold Down
15 8035426 1 Latch, RH - Filter Hold Down
16 8035388 1 Air Filter w/Seal - Closed Cab
17 8035427 1 Grommet
18 8035428 1 Plate, Grommet
19 8035429 1 Heater Unit
20 8035430 1 Foam, PSA 3/16 x 5/8 x 84"
21 8035431 5 Adapter, Hose 2-1/2" Dia.
22 8035397 24 Screw, Self Tapping #8-32 x 1/2"
23 8035432 2 Spring, Compression 1/2 x 7/8"
24 8035433 2 Bolt, Hex 5/16-18 x 1-1/2" Yellow
25 8035389 1 Foam Filter, Recirculate - Closed Cab
26 8035434 1 Holder, Foam Filter
27 8035435 2 Washer, Flat 5/16
28 7137741 1 Heater Hose, 5/8 x 126" Used with Both Engines
29 7137751 1 Heater Hose, 5/8 x 144" Cummins Engine Only
30 7129881 1 Heater Hose, 5/8 x 72" - Perkins Engine Only
31 8541036 1 Bushing, Hex 12P - 6P
32 8410009 8 Clamp, Hose SAE #10
33 8033032 1 Foam, PSA 1/8 x 3/8 x 164"
34 8360005 1 Valve, Shut-Off - Used with Both Engines
35 8420201 1 Connector, 5/8 x 12 NPT - Used with Both Engines
36 8584018 2 Mount, Tie
37 8584001 2 Plastic Tie
38 8035406 10 Plastic Tie
39 8526036 1 Threadlocker 242 General Purpose (.02 fl. oz.)
3606 Origin 9/99
2.28
Wet Arm Kit
Included in
Item 10
FRONT WINDSHIELD WIPER
(Optional)
10
42
35
36
44
8
34
33
43
37
Skylight
41
Windshield
Washer
Pump
Motor
(Ref.)
36
38
Front Windshield
Washer Pump Motor
40
39
30
21
9
23
19
18
1
32
20
27
28
PS0900
19
18
Cab
(Ref.)
3
2
14
2.29
15
10
31
12
17
16
11
13
22
24
7
6
5
29
4
26
Kit
PF0791
SUB-ASSEMBLY ROTATED FOR CLARITY
25
3606 Origin 9/99
FRONT WINDSHIELD WIPER
(Optional)
Item No. Part Number Qty. Description
1 8866492 1 Pivot Arm and Shaft Assembly (Includes Items 2 thru 9)
2 NSS 1 Nut, Acorn 3/8-24 (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
3 NSS 1 Washer, Int. Tooth Lock 3/8" (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
4 NSS 1 Driver, Knurled (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
5 NSS 1 Cap, Rubber (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
6 NSS 1 Nut, Hex Jam 11/16-24 (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
7 NSS 1 Washer, Metal (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
8 NSS 1 Washer, Cardboard (Serviced Only In Pivot Arm & Shaft Assy, Item 1)
9 8035408 1 Shaft Assembly
10 8035393 1 Wiper Arm, 24" Flex (Includes Wet Arm Kit)
11 8034815 1 Panto Adapter Kit (Includes Items 13, 15 & 16)
12 NSS 1 Gasket, Panto (Serviced Only In Panto Adapter Kit, Item 12)
13 8033856 2 Screw, Truss 1/4-20 x 3/4" Black
14 NSS 1 Nut, Acorn 1/4-28 (Serviced Only In Panto Adapter Kit, Item 12)
15 8310029 1 Washer, Internal Tooth Lock 1/4"
16 8307052 2 Washer, External Tooth Lock #10
17 8303839 2 Screw, Slotted Pan Head #10-32 x 1/2"
18 NSS 2 Clip, Spring (Serviced Only In Wiper Motor Assembly, Item 24)
19 NSS 2 Washer, Special Flat .560 x .251 x .015 (Serviced Only In Wiper Motor Assembly)
20 8035409 1 Link, Connecting
21 8305006 1 Nut, Hex Flanged 5/16-18
22 7112511 1 Wiper Motor Kit (Includes Item 24 - 27)
23 8033102 1 Wiper Motor Assembly (Includes Mtg Brkt, Motor, Link & Hardware)
24 NSS 1 Bracket, Wiper Motor
25 NSS 3 HHCS, Slotted 1/4-28 x 3/4"
26 8310002 3 Washer, External Tooth 1/4"
27 NSS 1 Pin, Shoulder (Serviced Only in Pivot Arm & Shaft Assy, Item 1)
28 8305005 1 Nut, Hex 1/4-28
29 8307203 3 Washer, Flat 5/16"
30 8035411 1 Drive Arm .95 Long
31 8033110 2 Screw, Hex 1/4-28 x 3/4" - Black
32 8035391 2 Nut, Center Lock - Black
33 91334019 1 Wet Arm Adapter
34 8035394 1 Grommet, Rubber 1/4" ID
35 8035392 1 Wiper Blade - 28"
36 8035395 1 Hose, Clear Vinyl - 144"
37 8035410 1 Washer Reservoir Assembly (Includes Reservoir, Cap & Pump Motors)
38 8035531 2 Pump Motor 12V
39 8303670 2 HHCS, 5/16-18 x 1"
40 8307203 2 Washer, Flat 5/16"
41 8305626 2 Nut, Hex Lock 5/16-18
42 8584001 1 Plastic Tie
43 7138250 1 Jumper Cable, Washer Bottle
44 8584018 1 Mount, Tie
3606 Origin 9/99
2.30
SKYLIGHT WINDSHIELD WIPER
(Optional)
9
10
8
Cab -
Ref.
99
11
13
3
7
1
6
12
5
4
2
14
2.31
15
Front Windshield
Washer Pump Motor (Ref.)
13
18
11
16
17
Skylight
Windshield
Washer
Pump
Motor
PS0910
3606 Origin 9/99
SKYLIGHT WINDSHIELD WIPER
(Optional)
Item No. Part Number Qty. Description
1 8035492 1 Motor, Skylight Wiper
2 8035493 1 Cover, Wiper
3 8035390 1 Wet Arm Adapter
4 8035494 2 Bolt, Socket Head #10-24 x 1-3/4"
5 8035495 4 Washer, Flat - Black (Zinc)
6 8035496 1 Clamp, Block 3/4"
7 8035497 1 Plate, Blind Nut
8 8035498 1 Blade, Wiper 20" Flex - Black
9 8035499 1 Wet Arm Kit
10 8035500 1 Arm, Wiper - Black
11 8035501 1 Hose, Clear
12 8035502 2 Clip, Wiring
13 8035503 1 Harness, Wiper
14 8035504 1 Conduit, Split 30"
15 8035505 1 Grommet 3/4" OD 1/2" ID
16 8035410 1 Washer Reservoir Assembly (Includes Reservoir, Cap & Pump Motors)
17 8035531 2 Pump Motor 12V
18 7138250 1 Jumper Wire, Washer Bottle
3606 Origin 7/99
2.32
REAR WINDOW & REAR WINDSHIELD WIPER
(Optional)
26 27 28 27 29
36
33
35
25
30
1
Comes with
Wiper Motor
Glass
(Ref)
31
Kit
PF0791
16
15
12
34
17
18
19
14
Glass
(Ref.)
10
32
13
23
11
Comes with
Wiper Arm
8
24
3
4
23
6
7
21
22
5
98
2
2.33
20
PS0920
3606 Origin 9/99
REAR WINDOW & REAR WINDSHIELD WIPER
(Optional)
Item No. Part Number Qty. Description
1 8035606 1 Rear Window Assembly (Includes Items 2-24)
2 8035474 1 Glass, Rear Window
3 8035475 2 Hinge, Plastic
4 8035476 2 Spacer, Hinge
5 8035414 4 Screw, Truss 1/4-20 x 1"
6 8035477 2 Grommet
7 8035478 2 Bushing, Plastic
8 8035468 6 Washer, Flat
9 8035479 2 Nut, Acorn 1/4-20
10 8035480 1 Hold, Open - LH
11 8035481 1 Hold, Open - RH
12 8035482 1 Bracket, Hold Open - LH
13 8035483 1 Bracket, Hold Open - RH
14 8035484 2 Pin, Detent Ring
15 8035485 2 Washer, Flat 1/4 ID x 9/16 OD
16 8035486 2 Pin, Roll
17 8035415 4 Washer, Flat 9/32 x 5/8" Black
18 8035416 4 Washer, Lock 1/4” Black
19 8035487 4 Screw, Truss Hd. 1/4-20 x 5/8" Black
20 8037206 1 Seal, Bulb “D”
21 8035488 1 Plug, Plastic 1/2" Dia.
22 8035489 1 Plug, Plastic 7/8" Dia.
23 8035490 2 Setting Block, 1/8 x 1/4 x 2"
24 8035491 2 Screw, Truss 1/4-20 x 1-1/4"
25 8035506 1 Motor, Wiper - Rear Window
26 8035507 1 Screw, Rd Hd #10-24 x 7/8"
27 8033087 2 Washer, Flat - Nylon Black
28 8034803 1 Grommet, Rubber T-Style
29 8034805 1 Nut, Acorn #10-24
30 8034808 1 Spacer, Nylon
31 8035500 1 Arm, Wiper Adj. Black
32 8035508 1 Blade, Wiper 14" Flex
33 8035509 1 Switch, Rocker SPST
34 8035510 1 Harness, Wire - Rear Wiper
35 8035511 1 Cover, Wiper Motor - Rear Window
36 8035501 1 Clip, Wiring - Adhesive Backed
3606 Origin 9/99
2.34
SOFT CAB ENCLOSURE
(Optional)
1
2
3
4
5
PS0840
2.35
3606 Origin 7/99
SOFT CAB ENCLOSURE
(Optional)
Item No. Part Number Qty. Description
1 7135682 1 Soft Cab Enclosure Kit - Complete (Includes Items 2 and 5)
2 7136352 1 Soft Cab Enclosure Kit (Includes Items 3 & 4 plus Installation Instructions)
3 7136832 1 Main Cab Enclosure - Soft
4 7136822 1 Door Section- Soft
5 7136302 1 Front Windshield Kit (Includes Installation Instructions)
3606 Origin 7/99
2.36
FENDERS
(Optional)
14
7
8
8
Torque to
222lb/ft
(300 Nm)
3
2
8
5
10
9
13
Front of Vehicle
11
Right Side
6
Left Side
4
PS0850
3
12
8
5
10
15
2.37
RIGHT SIDE SHOWN
1
16
Kit
it
K
PF0791
17
it
K
3606 Origin 7/99
FENDERS
(Optional)
Item No. Part Number Qty. Description
1 7140600 1 Four Fender Assembly - Complete (Includes Items 2 thru 15)
2 7132653 4 Fender - Millennia Series
3 7132921 8 Plate, Top Fender
4 7138350 2 Support, Fender - Left Side
5 8307005 16 Washer, Lock 3/8"
6 7138351 2 Support, Fender - Right Side
7 8303675 8 HHCS, 3/8-16 x 1-1/4"
8 8307110 32 Washer, Plain 3/8" SAE
9 8310388 16 HHCS, 3/8-16 x 1-1/4" Gr5
10 8305008 16 Nut, Hex 3/8-16
11 8406201 16 Clip, Tube 1"
12 7134922 4 Flap, Extension
13 8307049 16 Washer, Lock M16
14 8303621 8 HHCS, 3/8-16 x 1-1/2" Gr5
15 8520031 4 Fitting, Lube 90° (For easier access to top axle lubrication point)
16 7142800 1 Single Fender Kit - Left Side
17 7144500 1 Single Fender Kit - Right Side
3606 Origin 7/99
2.38
SECTION 3 – DRIVE TRAIN
DRIVE SHAFT - TRANSFER BOX TO FRONT AXLE
8
9
To
Transfer Box
1
7
Apply Threadlocker and
Torque to 83 lb/ft.
(112,5 Nm)
Typ. Both Ends
2
3
4
3.1
To Front Axle
7
5
9
8
10
6
PH0940
This Is A Balanced
3
Assembly, If Replacing
Items 2, 4 or 6 Order
Item1
2
PS0151
3606 Rev 5/99
DRIVE SHAFT - TRANSFER BOX TO FRONT AXLE
Item No. Part Number Qty. Description
1 7128952 1 Drive Shaft Assembly (Consists of Items 2 thru 6)
2 NSS 2 Yoke, Flange (See Note)
3 8035106 2 Cross and Bearing Assembly
4 NSS 1 Tube Assembly (See Note)
5 8035109 1 Dust Cap Kit
6 NSS 1 Yoke, Slip (See Note)
7 8310297 8 HHCS, M12-1,75 x 35mm
8 8310356 8 Washer, Flat M12 Hardened
9 8307025 8 Washer, Lock M12
10 8526036 AR Threadlocker 242 General Purpose (.02 fl. oz.)
This is a balanced assembly. When servicing Items 2, 4 or 6 order Item 1
NOTE:
3606 Rev 5/99
3.2
DRIVE SHAFT - TRANSFER BOX TO REAR AXLE
8
1
9
To
Transfer Box
7
Apply Threadlocker and
Torque to 83 lb/ft.
(112,5 Nm)
Typ. Both Ends
2
3
4
To Rear axle
3.3
7
5
9
8
10
6
PH0940
3
This Is A Balanced
Assembly, If Replacing
Items 2, 4 or 6 Order
2
Item1
PS0161
3606 Rev 5/99
DRIVE SHAFT - TRANSFER BOX TO REAR AXLE
Item No. Part Number Qty. Description
1 7128932 1 Drive Shaft Assembly (Consists of Items 2 thru 6)
2 NSS 2 Yoke, Flange (See Note)
3 8035106 2 Cross and Bearing Assembly
4 NSS 1 Tube Assembly (See Note)
5 8035109 1 Dust Cap Kit
6 NSS 1 Yoke, Slip (See Note)
7 8310297 8 HHCS, M12-1,75 x 35mm
8 8310356 8 Washer, Flat M12 Hardened
9 8307025 8 Washer, Lock M12
10 8526036 AR Threadlocker 242 General Purpose (.02 fl. oz.)
This is a balanced assembly. When servicing Items 2, 4 or 6 order Item 1
NOTE:
3606 Rev 5/99
3.4
DRIVE SHAFT - TRANSMISSION TO TRANSFER BOX
8
1
9
To Transfer Box
7
Apply Threadlocker and
Torque to 83 lb/ft.
(112,5 Nm)
Typ. Both Ends
2
3
4
To
Transmission
3.5
7
5
9
8
10
6
PH0940
3
This Is A Balanced
Assembly, If Replacing
Items 2, 4 or 6 Order
Item1
2
PS0171
3606 Rev 5/99
DRIVE SHAFT - TRANSMISSION TO TRANSFER BOX
Item No. Part Number Qty. Description
1 7128942 1 Drive Shaft Assembly (Consists of Items 2 thru 6)
2 NSS 2 Yoke, Flange (See Note)
3 8035106 2 Cross and Bearing Assembly
4 NSS 1 Tube Assembly (See Note)
5 8035109 1 Dust Cap Kit
6 NSS 1 Yoke, Slip (See Note)
7 8310297 8 HHCS, M12-1,75 x 35mm
8 8310356 8 Washer, Flat M12 Hardened
9 8307025 8 Washer, Lock M12
10 8526036 AR Threadlocker 242 General Purpose (.02 fl. oz.)
NOTE:
This is a balanced assembly. When servicing Items 2, 4 or 6 order Item 1
3606 Rev 7/98
3.6
TRANSFER BOX HOUSING AND COVERS
1
2
3
11
14
10
12
13
13
12
4
5
9
6
7
8
3
6
7
8
3
6
7
8
15
16
3.7
PS0190
3606 Origin 7/98
TRANSFER BOX HOUSING AND COVERS
Item No. Part Number Qty. Description
1 8841031 1 Transfer Box Assembly (Consists of Items 2 thru 16)
2 8035240 1 Housing, Transfer Box
3 8033626 3 Bearing
4 8033631 1 Washer
5 8033623 1 Snap Ring
6 8033628 AR Shim, 0,30mm
7 8033629 AR Shim, 0,10mm
8 8033630 AR Shim, 0,05mm
9 8033627 1 O-ring
10 8033622 1 Cover, Shaft
11 8033604 3 Bolt, M12 x 30mm
12 8033618 2 Cover
13 8035241 8 Bolt, M8 x 22mm
14 8035242 1 Shaft
15 8033624 1 Ring, Oil Seal
16 8033625 1 Bearing
3606 Origin 7/98
3.8
TRANSFER BOX GEARS AND SHAFTS
1
9
10
11
2
3
4
6
5
7
8
2
12
12
12
13
13
17
14
14
16
15
15
23
22
24
18
19
25
26
27
28
29
20
21
3.9
2
PS0180
3606 Origin 7/98
TRANSFER BOX GEARS AND SHAFTS
Item No. Part Number Qty. Description
1 8841031 1 Transfer Box Assembly (Consists of Items 2 thru 29)
2 8035243 3 Plug, Oil M22-1,5
3 8033608 1 Washer
4 8033613 1 Bolt
5 8033609 1 Washer
6 8033612 1 Breather, M10-1
7 8033619 1 Extension, Breather
8 8033610 1 Washer
9 8035244 1 Shaft
10 8033624 1 Ring, Oil Seal
11 8033625 1 Bearing
12 8033633 4 Gear Z=37
13 8033632 2 Pin, Gear
14 8033626 2 Bearing
15 8033614 2 Plug
16 8033611 1 O-Ring
17 8033594 1 Bearing
18 8033591 1 Ring, Oil Seal
19 8033599 1 Spacer
20 8033603 5 Bolt, M10 x 30mm
21 8033620 1 Cover, Drop Box
22 8033590 1 Nut, Ring M25-1,5
23 8033596 1 O-Ring
24 8033597 1 Ring, Centering
25 8033595 1 O-Ring
26 8035245 1 Flange
27 8033615 AR Shim, 0,10mm
28 8033616 AR Shim, 0,19mm
29 8033617 AR Shim, 0,35mm
3606 Origin 7/98
3.10
AXLE HOUSING - FRONT AXLE
1
27
2
28
3
2
30
33
34
6
7
36
35
8
37
4
15
4
5
13
12
9
2
11
10
27
16
31
6
14
28
29
2
18
Front Of Vehicle
9
32
27
17
20
21
22
23
3.11
19
25
24
26
PS0200
3606 Origin 7/98
AXLE HOUSING - FRONT AXLE
Item No. Part Number Qty. Description
1 8035114 1 Beam Trumpet - Left Front
2 8035115 4 O-Ring
3 8035116 1 Brake Flange - Left Front
4 8035117 2 O-Ring
5 8035118 1 Bushing
6 8035119 4 Bushing
7 8035120 1 Support, Rear
8 8035121 1 Bolt
9 8035122 2 Grease Nipple M8-1
10 8035123 1 Washer, Thrust
11 8035124 1 Bushing
12 8035125 1 Bushing
13 8035126 1 O-Ring
14 8035127 1 Bushing
15 8035128 1 Washer, Thrust
16 8035129 1 Brake Flange - Right Front
17 8035130 1 Beam Trumpet - Right Front
18 8035131 1 Breather M10-1
19 8035132 24 Bolt
20 8035133 2 Washer, Belleville
21 8035134 2 Shim
22 8035135 2 Bushing
23 8035136 2 Bushing
24 8035137 2 Seal, Oil
25 8035138 2 Bearing, Spherical
26 8035139 2 Washer, Belleville
27 8033582 3 Plug, Oil M30-2
28 8033561 4 Breather M10-1
29 8035140 4 Bolt M12 x 110mm
30 8035141 1 Body, Central
31 8035142 1 Support, Front
32 8035143 1 Bolt
33 8035144 6 Washer
34 8035145 6 Ring, Snap Internal
35 8035146 6 Bolt, M16-1,5
36 8035147 6 O-Ring
37 8035148 6 Pin
3606 Rev. 9/99
3.12
AXLE HOUSING - REAR AXLE
1
6
7
Front Of Vehicle
11
31
6
14
9
29
32
17
25
27
20
21
22
23
24
28
2
18
19
27
2
3
4
13
12
8
28
2
15
4
5
9
10
30
27
2
16
3.13
26
PS0280
3606 Origin 7/98
AXLE HOUSING - REAR AXLE
Item No. Part Number Qty. Description
1 8035114 1 Beam Trumpet - Right Rear
2 8035115 4 O-Ring
3 8035236 1 Brake Flange - Right Rear
4 8035117 2 O-Ring
5 8035118 1 Bushing
6 8035119 4 Bushing
7 8035120 1 Support, Rear
8 8035121 1 Bolt
9 8035122 2 Grease Nipple M8-1
10 8035123 1 Washer, Thrust
11 8035124 1 Bushing
12 8035125 1 Bushing
13 8035126 1 O-Ring
14 8035127 1 Bushing
15 8035128 1 Washer, Thrust
16 8035237 1 Brake Flange - Left Rear
17 8035130 1 Beam Trumpet - Left Rear
18 8035131 1 Breather M10-1
19 8035132 24 Bolt
20 8035133 2 Washer, Belleville
21 8035134 2 Shim
22 8035135 2 Bushing
23 8035136 2 Bushing
24 8035137 2 Seal, Oil
25 8035138 2 Bearing, Spherical
26 8035139 2 Washer, Belleville
27 8033582 3 Plug, Oil M30-2
28 8033561 2 Breather M10-1
29 8035140 4 Bolt, M12 x 110mm
30 8035141 1 Body, Central
31 8035142 1 Support, Front
32 8035143 1 Bolt
3606 Origin 7/98
3.14
STEER CYLINDER AND SWIVELS - FRONT AXLE
10
1
2
3
8
5
4
6
7
23
26
24
25
11
17
16
12
13
14
18
19
21
18
9
20
22
19
10
Looking Toward Front
of Vehicle
(Input Side Of Axle)
3.15
15
PS0210
3606 Rev 4/04
STEER CYLINDER AND SWIVELS - FRONT AXLE
Item No. Part Number Qty. Description
1 8035149 1 Housing, Swivel - Left Side (See Note on Art)
2 8033510 4 Nut, Hex M14 (Axle S/N 101 thru 107)
8035302 4 Nut, Hex M16 (Axle S/N 108 & After)
3 8035150 4 Bolt, M14 x 95mm (Axle S/N 101 thru 107)
8035303 4 Bolt, M16 x 100mm (Axle S/N 108 & After)
4 8035249 1 Steering Arm Assembly - Left Side (Includes Items 5 thru 7)
5 8035248 1 Arm, Steering - Left Side (See Note on Art)
6 8035152 1 Nut, M24-1,5
7 8035151 1 Ball Joint
8 8035304 1 Cylinder, Steering (Axle S/N 101 thru 107)
9 8035252 1 Head, Cylinder (Axle S/N 101 thru 107)
10 8035152 2 Nut M24-1,5
11 8035254 1 Steering Arm Assembly - Right Side (See Note on Art) (Includes Items 12 thru 14)
12 8035151 1 Ball Joint
13 8035152 1 Nut, M24-1,5
14 8035251 1 Arm, Steering - Right Side (See Note on Art)
15 8035253 1 Kit, Oil Seal
16 8035153 2 Bushing
17 8035154 2 Seal, Oil
18 8035155 16 Bolt, M16-2 x 38mm
19 8035156 4 Grease Nipple M6-1
20 8035157 2 King Pin - Upper
21 8035158 1 Housing, Swivel - Right Side (See Note on Art)
22 8035159 2 King Pin - Lower
23 8035255 2 Bolt, M22-1,5 x 55mm
24 8035256 2 Bushing
25 8035223 2 Bolt, M14-1,5 x 65mm
26 91474088 1 Rod, Steering Cylinder
8035250 1 Cylinder, Steering (Axle S/N 108 & After)
8035305 1 Head, Cylinder (Axle S/N 108 & After)
When replacing items 1 or 21 on axle S/N 101 thru 107 also order item 2 part
NOTE:
number 8035302 and item 3 part number 8035303.
3606 Rev 4/04
3.16
STEER CYLINDER AND SWIVELS - REAR AXLE
18
1
19
20
10
2
3
8
5
4
6
7
23
26
24
25
17
16
21
22
18
14
13
11
9
12
19
10
Looking Toward Rear
of Vehicle
(Input Side Of Axle)
3.17
15
PS0210
3606 Rev. 4/04
STEER CYLINDER AND SWIVELS - REAR AXLE
Item No. Part Number Qty. Description
1 8035149 1 Housing, Swivel - Left Side (See Note on Art)
2 8033510 4 Nut, Hex M14 (Axle S/N 101 thru 112)
8035302 4 Nut, Hex M16 (Axle S/N 113 & After)
3 8035150 4 Bolt, M14 x 95mm (Axle S/N 101 thru 112)
8035303 4 Bolt, M16 x 100mm (Axle S/N 113 & After)
4 8035249 1 Steering Arm Assembly - Left Side (See Note on Art) (Includes Items 5 thru 7)
5 8035248 1 Arm, Steering - Left Side (See Note on Art)
6 8035152 1 Nut, M24-1,5
7 8035151 1 Ball Joint
8 8035304 1 Cylinder, Steering (Axle S/N 101 thru 112)
9 8035252 1 Head, Cylinder (Axle S/N 101 thru 112)
10 8033894 2 Nut, M24-1,5
11 8035254 1 Steering Arm Assembly - Right Side (See Note on Art) (Includes Items 12 thru 14)
12 8035151 1 Ball Joint
13 8035152 1 Nut, M24-1,5
14 8035251 1 Arm, Steering - Right Side (See Note on Art)
15 8035253 1 Kit, Oil Seal
16 8035153 2 Bushing
17 8035154 2 Seal, Oil
18 8035155 16 Bolt, M16- 2 x 38mm
19 8035156 4 Grease Nipple M6-1
20 8035157 2 King Pin - Upper
21 8035158 1 Housing, Swivel - Right Side (See Note on Art)
22 8035159 2 King Pin - Lower
23 8035255 2 Bolt, M22-1,5 x 55mm
24 8035256 2 Bushing
25 8035223 2 Bolt, M14-1,5 x 65mm
26 91474088 1 Rod, Steering Cylinder
8035250 1 Cylinder, Steering (Axle S/N 113 & After)
8035305 1 Head, Cylinder (Axle S/N 113 & After)
When replacing items 1 or 21 on axle S/N 101 thru 112 also order item 2 part
NOTE:
number 8035302 and item 3 part number 8035303.
3606 Rev. 4/04
3.18
DIFFERENTIAL ASSEMBLY - FRONT AXLE
6
9
5
4
10
11
12
8
6
5
7
1
2
3
2
7
8
3.19
PS0230
3606 Origin 7/98
DIFFERENTIAL ASSEMBLY - FRONT AXLE
Item No. Part Number Qty. Description
1 8035176 1 Kit, Differential (Includes Items 2 and 3)
2 8035177 4 Washer, Thrust
3 8035178 2 Shaft
4 8035179 1 Differential Housing - Two Halves
5 8035180 2 Bolt, M6-1 x 10mm
6 8035181 2 Plate, Locking
7 8035182 2 Nut, Ring
8 8035183 2 Bearing
9 8033544 12 Bolt, M10-1,5 x 75mm
10 8035184 2 Plate
11 8035185 10 Plate, Drive
12 8035186 8 Plate
3606 Origin 7/98
3.20
BEVEL GEAR AND PINION SET - FRONT/REAR AXLES
22
21
20
19
18
17
17
3
4
5
6
5
1
2
7
8
9
10
11
12
13
14
15
16
3.21
PS0220
3606 Origin 7/98
BEVEL GEAR AND PINION SET - FRONT/REAR AXLES
Item No. Part Number Qty. Description
NOTE: Quantities listed below are for one complete axle
1 8035257 1 Bevel Gear And Pinion Set - Front Axle (Includes Items 3 thru 6)
2 8035258 1 Bevel Gear And Pinion Set - Rear Axle (Includes Items 3 thru 6)
3 8033536 1 Lockwasher
4 8033537 1 Nut, Ring M40-1,5
5 8033541 2 Washer
6 8033540 1 Spacer, Collapsible
7 8035160 AR Shim, 2,50mm
8 8035161 AR Shim, 2,60mm
9 8035162 AR Shim, 2,70mm
10 8035163 AR Shim, 2,80mm
11 8035164 AR Shim, 2,90mm
12 8035165 AR Shim, 3,00mm
13 8035166 AR Shim, 3,10mm
14 8035167 AR Shim, 3,20mm
15 8035168 AR Shim, 3,30mm
16 8035169 AR Shim, 3,40mm
17 8035170 2 Bearing
18 8035171 1 Washer
19 8035172 1 O-Ring
20 8035173 1 Seal, Oil
21 8035174 1 Flange
22 8035175 1 Snap Ring
3606 Origin 7/98
3.22
BRAKE ASSEMBLY - FRONT AXLE
19
20
21
8
9
10
11
12
13
22
18
1
2
3
14
15
16
2
17
4
5
6
5
6
5
6
7
3.23
PS0250
3606 Origin 7/98
BRAKE ASSEMBLY - FRONT AXLE
Item No. Part Number Qty. Description
NOTE: Quantities listed below are for one complete axle
1 8033575 2 Quadring
2 8035196 4 Quadring
3 8035197 2 Piston, Brake (Positive)
4 8035198 2 Plate, Drive
5 8035199 6 Disc, Brake
6 8035200 6 Plate, Drive
7 8035201 2 Sleeve
8 8035216 2 Kit, Self-Adjust (Includes Items 9 thru 13)
9 NSS 3 Washer, Belleville
10 NSS 3 Pin, Split
11 NSS 3 Spacer
12 NSS 18 Washer, Belleville
13 NSS 3 Bolt
14 8035207 2 Ring
15 8035208 2 Sleeve
16 8035209 4 Washer, Belleville
17 8035210 2 Piston, Brake (Negative)
18 8035211 2 Quadring
19 8035212 6 Washer
20 8035213 6 O-Ring
21 8035214 6 Shaft
22 8035215 6 O-Ring
3606 Origin 7/98
3.24
BRAKE ASSEMBLY - REAR AXLE
8
9
10
11
12
13
1
2
3
4
5
6
14
7
3.25
PS0300
3606 Origin 7/98
BRAKE ASSEMBLY - REAR AXLE
Item No. Part Number Qty. Description
NOTE: Quantities listed below are for one complete axle
1 8033575 2 Quadring
2 8035196 4 Quadring
3 8035197 2 Piston, Brake (Positive)
4 8035198 2 Plate, Drive
5 8035199 2 Disc, Brake
6 8035200 2 Plate, Drive
7 8035201 2 Sleeve
8 8035216 2 Kit, Self-Adjust (Includes Items 9 thru 13)
9 NSS 3 Washer, Belleville
10 NSS 3 Pin, Split
11 NSS 3 Spacer
12 NSS 18 Washer, Belleville
13 NSS 3 Bolt
14 8035239 4 Plate, Drive
3606 Origin 7/98
3.26
REDUCTION GEARS - FRONT/REAR AXLES
2
3
4
10
5
6
7
9
8
PS0270
3.27
3606 Origin 7/98
REDUCTION GEARS - FRONT/REAR AXLES
Item No. Part Number Qty. Description
NOTE: Quanties listed below are for one complete axle
1 8035226 6 Bolt, M10-1,25 x 50mm
2 8035227 6 Pin
3 8035228 6 Washer, Thrust
4 8035229 6 Washer, Thrust
5 8035230 6 Gear, Planetary
6 8035231 17 Bearing, Needle (sold in sets of ten - 168 bearings required)
7 8035232 6 Washer, Thrust
8 91474169 2 Planetary Carrier Assembly (Includes Item 8)
9 8035234 1 Pad
10 8033582 2 Plug, Oil M30-2
11 8035235 4 Bolt, M8 x 20mm
3606 Origin 7/98
3.28
WHEEL HUB ASSEMBLY - FRONT/REAR AXLES
1
10
11
6
7
8
9
2
12
4
3
4
5
PS0260
3.29
3606 Origin 7/98
WHEEL HUB ASSEMBLY - FRONT/REAR AXLES
Item No. Part Number Qty. Description
NOTE: Quantities listed below are for one complete axle
1 8035218 2 Wheel Hub Assembly (Includes Item 2)
2 8035217 10 Stud
3 8035219 2 O-Ring
4 8030464 4 Bearing
5 8035220 2 Lockring
6 8035221 2 Carrier, Wheel
7 8035222 2 Gear, Crown Z=77
8 8030470 16 Bushing, Centering
9 8035223 16 Bolt, M14-1,5 x 65mm
10 8035224 20 Washer
11 8035225 20 Nut, M22-1,5
12 8033557 2 Seal, Cassette
3606 Origin 7/98
3.30
AXLE SHAFTS - FRONT/REAR AXLES
1
2
5
4
3
8
9
7
6
5
4
PS0240
3.31
3606 Origin 7/98
AXLE SHAFTS - FRONT/REAR AXLES
Item No. Part Number Qty. Description
NOTE: Quanties listed below are for one complete axle
1 8035187 2 Drive Shaft Assembly (Includes Items 2 thru 6)
2 8035188 1 Shaft, Half - Differential Side
3 8035189 1 Body, Central
4 8035190 2 Spider Assembly (Includes Item 5)
5 8035191 4 Snap Ring
6 8035192 1 Shaft, Half - Wheel Side
7 8035193 4 Washer, Thrust
8 8035194 2 Washer
9 8035195 2 Snap Ring
3606 Origin 7/98
3.32
DIFFERENTIAL ASSEMBLY - REAR AXLE
10
9
7
6
5
8
1
2
3
4
2
4
8
5
6
7
PS0290
3.33
3606 Rev 5/02
DIFFERENTIAL ASSEMBLY - REAR AXLE
Item No. Part Number Qty. Description
1 8036488 1 Kit, Differential (Includes Items 2, 3 and 4)
2 8035177 4 Washer, Thrust
3 8035178 2 Shaft
4 8035238 2 Plate, Drive
5 8035180 2 Bolt, M6-1 x 10mm
6 8035181 2 Plate, Locking
7 8035182 2 Nut, Ring
8 8035183 2 Bearing
9 8033544 12 Bolt, M10-1,5 x 75mm
10 8035179 1 Differential Housing - Two Halves
3606 Rev 5/02
3.34
TRANSMISSION CASE, PLATE & CONVERTER HOUSING
(4 Speed)
26
28
33
21
31
32
34
25
24
35
39
36
38
17
37
12
21
40
16
41
3
4
10
25
32
33
31
42
1
2
4
3
4
5
8
3
6
7
6
7
23
22
3
21
30
21
21
13
14
15
11
12
PF0760
29
4
4
21
22
20
27
3
4
24
25
4
4
3
21
26
18
19
9
43
PS0010
3.35
3606 Rev 9/99
TRANSMISSION CASE, PLATE & CONVERTER HOUSING
(4 Speed)
Item No. Part Number Qty. Description
1 8034965 1 Dipstick Assembly
2 8034964 1 Tube, Dipstick
3 8034930 8 Plug
4 8034931 8 O-Ring
5 8034947 1 Plug, Sensor Port
6 8034949 2 Plug, Oil Level
7 8034948 2 O-Ring - Oil Level Plug
8 8034945 1 Case, Transmission
9 8034950 1 Tube And Screen Assembly
10 8034951 1 Seal Ring, Oil Supply Tube
11 8034956 1 Retainer Clip, Oil Supply Tube
12 8034953 2 Washer, Seal
13 8034955 1 Nut, Clip Retainer Screw
14 8034954 1 Washer, Clip Retainer Screw
15 8034952 1 Screw, Retainer Clip
16 8032528 1 Drain Plug, Magnetic
17 8034966 1 Screw
18 8034932 1 Gasket, Converter Housing To Plate
19 8034933 1 Housing, Converter
20 8035092 1 Plug, Temperature Pickup
21 8034934 32 Washer, Lock
22 8034935 16 Screw
23 8034936 6 Screw
24 8032508 2 Plug
25 8034942 3 Plug
26 8034936 7 Screw
27 8034960 2 Screw
28 8034963 1 Seat, Safety Valve
29 8034962 1 Spring, Safety Valve
30 8034961 1 Washer, Poppet
31 8034939 2 O-Ring - Sensor
32 8034938 2 Plug, Sensor Port
33 8034940 2 Screw, Speed Sensor Plug
34 8034941 1 Plate, Spacer
35 8034959 1 Snap Ring - Seat
36 8034958 1 Poppet, Converter Safety Valve
37 8034957 1 Plug, Drain Back Port
38 8034944 2 Pin, Dowel - Spacer Plate To Transmission Case
39 8034943 1 Gasket, Spacer Plate To Transmission Case
40 8034937 1 Screw, Transmission Case To Spacer Plate
41 8034946 1 Plug, Filler
42 8032509 1 Breather, Air
KITS
43 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.36
TORQUE CONVERTER AND DRIVE PLATES
(4 Speed)
3
2
5
4
6
13
11
12
11
9
10
7
8
1
22
3.37
23
21
20
19
18
14
14
15
16
17
24
PF0760
PS0030
3606 Origin 9/99
TORQUE CONVERTER AND DRIVE PLATES
(4 Speed)
Item No. Part Number Qty. Description
1 8034981 1 Snap Ring, Stator Support
2 8034980 1 Washer, Impeller Hub Gear
3 8034978 1 Stator Support Assembly (Includes Items 4 and 5)
4 8034979 1 Bushing
5 8034982 1 Bearing
6 8034977 1 Piston Ring Expander, Stator Support
7 8034976 1 Piston Ring, Stator Support
8 8034975 1 Snap Ring, Stator Support
9 8034974 1 Gear, Impeller Hub (35T)
10 8034973 1 Bearing, Torque Converter
11 8034971 2 O-Ring, Oil Distributor Ring
12 8034972 1 Ring, Oil Distributor
13 8034970 1 Oil Seal, Converter Housing
14 8034968 2 Snap Ring, Impeller Hub
15 8034969 1 Torque Converter Assembly
16 8034967 1 O-Ring, Torque Converter Plug
17 8032599 1 Plug, Torque Converter
18 8032600 1 Snap Ring, Plug
19 8035088 1 Drive Plate Assembly Kit (Includes Items 20 thru 23)
20 NSS Drive Plate
21 8032602 1 Backing Ring, Drive Plate
22 8307005 6 Washer, Lock - Drive Plate Mounting
23 8035087 6 Screw, Drive Plate Mounting
KITS
24 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Rev 3/02
3.38
CHARGING PUMP, DRIVE, FILTER & REVERSE IDLER
(4 Speed)
13
12
11
12
13
9
10
9
8
1
4
3
2
1
5
35
34
37
36
38
6
7
21
22
23
24
20
31
30
29
18
26
14
15
16
17
19
25
27
28
3.39
33
32
39
40
PF0760
PS0940
PS0050
3606 Origin 7/98
CHARGING PUMP, DRIVE, FILTER & REVERSE IDLER
(4 Speed)
Item No. Part Number Qty. Description
1 8034983 2 Thrust Washer, Pump Drive Idler
2 8034984 1 Bearing, Idler Gear
3 8034985 1 Gear, Pump Drive Idler (31T)
4 8034986 1 Pump Drive Idler Shaft And Pin Assembly (Includes Item 5)
5 8034987 1 Pin, Roll
6 8034988 1 Bearing, Pump Drive Gear
7 8034989 1 Gear, Pump Drive (34T)
8 8034990 1 Bearing, Pump Drive Gear
9 8034996 2 Gasket, Adaptor
10 8034997 1 Adaptor, Pump To Plate
11 8034998 1 Stud, Pump Mounting
12 8034999 5 Washer, Lock - Pump Mounting Stud
13 8035000 5 Nut, Pump Mounting Stud
14 8035001 4 Stud, Pump Mounting
15 8035090 1 Pump, Charging
16 8035002 1 Nut, Pump Mounting
17 8034934 1 Washer, Lock - Pump Mounting Stud
18 8035003 1 Stud, Pump Mounting
19 8035004 1 Filter Assembly (Also Included in Filter Kit, Item 40)
20 8035009 1 Regulator Valve Assembly (Includes Items 21 thru 24)
21 8035005 1 Piston
22 8035006 1 Spring
23 8035007 1 Pin
24 8035008 1 Sleeve
25 8035016 1 Capscrew, Reverse Idler End Plate
26 8035015 1 Washer, End Plate Capscrew
27 8035017 1 Roll Pin, End Plate To Shaft
28 8035014 1 Plate, End
29 8034917 1 Gear, Reverse Idler (28T)
30 8035013 1 Bearing, Reverse Idler Gear
31 8035012 1 Washer, Thrust
32 8035011 1 Shaft, Idler And Pilot
33 8035010 1 Snap Ring, Idler Shaft
34 8034992 1 Ball Check Valve Assembly (Includes Items 35 thru 38)
35 8034991 1 O-Ring
36 8034993 1 Pin
37 8034994 1 Ball
38 8034995 1 Spring
KITS
39 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
40 7138298 1 1000 Hour Filter Kit for Cummins Turbo (Includes 6 Filters; Engine Oil Filter,
7138299 1 1000 Hour Filter Kit for Perkins Natural
7138432 1 1000 Hour Filter Kit for Perkins Turbo
3606 Rev 9/99
Fuel Filter, Both Air Filters, Transmission Oil Filter & Hydraulic Oil Filter
(Includes 6 Filters; Engine Oil Filter,
Fuel Filter, Both Air Filters, Transmission Oil Filter & Hydraulic Oil Filter
(Includes 6 Filters; Engine Oil Filter,
Fuel Filter, Both Air Filters, Transmission Oil Filter & Hydraulic Oil Filter
3.40
FORWARD AND REVERSE SHAFT GROUP
(4 Speed)
13
11
10
9
8
7
2
2
4
6
2
3
2
1
14
11
5
5
15
3
17
18
16
9
17
2
8
REVERSE
16
21
2
19
3
7
12
13
14
15
2
2
22
3
20
20
3.41
12
23
24
10
FORWARD
25
26
PF0760
PS0070
3606 Origin 7/98
FORWARD AND REVERSE SHAFT GROUP
(4 Speed)
Item No. Part Number Qty. Description
1 8034982 1 Bearing, Front Turbine Shaft
2 8035018 8 Washer, Thrust - Clutch Gear
3 8035019 4 Bearing, Clutch Gear Thrust Washer
4 8034920 1 Reverse Clutch Gear And Bearing Assembly (Includes Items 5 and 6)
5 8034918 2 Bearing
6 8034919 1 Spacer
7 8035020 2 Snap Ring, End Plate
8 8035021 2 Plate, End
9 8035022 12 Inner Disc - Clutch
10 8035023 12 Outer Disc - Clutch
11 8035024 2 Snap Ring, Retainer
12 8035025 2 Retainer, Snap Ring
13 8035026 2 Disc Washer (Spring) Assembly (Consists Of 5 Washers)
14 8035027 2 Wear Plate, Clutch Piston
15 8035028 2 Clutch Piston And Seals assembly (Includes Items 16 and 17)
16 8035029 1 Seal, Clutch Piston - Outer
17 8035030 1 Seal, Clutch Piston - Inner
18 8035031 1 Turbine Shaft Drum And Plug Assembly
19 8034921 1 Forward Clutch Gear And Bearing Assembly (Includes Items 20 and 21)
20 8034918 2 Bearing
21 8034919 1 Spacer
22 8035032 1 Bearing, Rear Turbine Shaft
23 8035033 3 Ring, Piston
24 8035034 1 Sleeve, Oil Distributor
25 8035035 1 Screw, Retainer
KITS
26 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.42
FIRST AND SECOND SHAFT GROUP
(4 Speed)
7
8
6
4
3
1
2
10
9
16
5
5
11
19
18
17
10
6
FIRST
6
19
5
5
12
20
5
15
14
13
21
16
17
18
5
6
5
5
23
22
25
24
3.43
14
13
12
26
9
11
SECOND
27
PF0760
PS0090
3606 Origin 7/98
FIRST AND SECOND SHAFT GROUP
(4 Speed)
Item No. Part Number Qty. Description
1 8035036 1 Screw, Locating Sleeve
2 8035050 1 Sleeve, Oil Distributor
3 8035033 2 Ring, Piston
4 8035038 1 Bearing And Seal Assembly
5 8035018 8 Washer, Thrust - Clutch Gear
6 8035019 4 Bearing, Clutch Gear Thrust Washer
7 8034925 1 First Clutch Gear And Bearing Assembly (Includes Item 8)
8 8034918 2 Bearing
9 8035020 2 Snap Ring, End Plate
10 8035021 2 Plate, End
11 8035022 15 Inner Disc - Clutch (10 Required for First and 5 Required for Second)
12 8035023 15 Outer Disc - Clutch (10 Required for First and 5 Required for Second)
13 8035024 2 Snap Ring, Retainer
14 8035025 2 Retainer, Snap Ring
15 8035051 1 First Clutch Disc Spring Assembly (Consists Of 7 Spring Washers)
16 8035027 2 Wear Plate, Clutch Piston
17 8035052 2 Clutch Piston And Seal Assembly (Includes Items 18 and 19)
18 8035029 1 Seal, Clutch Piston - Outer
19 8035030 1 Seal, Clutch Piston - Inner
20 8035053 1 First And Second Shaft, Drum And Plug Assembly
21 8035026 1 Second Clutch Disc Spring Assembly (Consists Of 5 Spring Washers)
22 8034926 1 Second Clutch Gear And Bearing Assembly (Includes Item 23)
23 8034927 2 Bearing
24 8035039 2 Snap Ring, Second Clutch Gear Hub
25 8034928 1 Gear, Third Driven
26 8035054 1 Bearing, Rear
KITS
27 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.44
HIGH, THIRD AND OUTPUT SHAFT GROUP
(4 Speed)
9
10
10
8
6
5
4
3
1
2
16
18
17
7
11
7
19
14
8
20
22
13
12
7
7
23
21
8
7
24
25
7
22
14
21
20
HIGH
19
18
28
15
27
15
17
16
THIRD
29
12
13
28
32
31
30
33
PF0760
3.45
26
PS0080
3606 Origin 7/98
HIGH, THIRD AND OUTPUT SHAFT GROUP
(4 Speed)
Item No. Part Number Qty. Description
1 8035036 1 Screw, Locating Sleeve
2 8035037 1 Sleeve, Oil Distributor
3 8035033 2 Ring, Piston
4 8035038 1 Bearing And Seal Assembly
5 8034922 1 Gear, First Drive
6 8035039 2 Snap Ring, Gear Hub
7 8035018 6 Washer, Thrust - Clutch Gear
8 8035019 3 Bearing, Clutch Gear Thrust Washer
9 8034923 1 Fourth Clutch Gear And Bearing Assembly (Includes Items 10 and 11)
10 8034918 2 Bearing
11 8034919 1 Spacer, Bearing
12 8035020 2 Snap Ring, End Plate
13 8035021 2 Plate, End
14 8035022 11 Inner Disc - Clutch (6 Required for High and 5 Required for Third)
15 8035023 11 Outer Disc - Clutch (6 Required for High and 5 Required for Third)
16 8035024 2 Snap Ring, Retainer
17 8035025 2 Retainer, Snap Ring
18 8035026 2 Disc Washer (Spring) Assembly (Consists Of 5 Washers)
19 8035027 2 Wear Plate, Clutch Piston
20 8035040 2 Clutch Piston And Ball Seat Assembly (Includes Items 21 and 22)
21 8035029 1 Seal, Clutch Piston - Outer
22 8035030 1 Seal, Clutch Piston - Inner
23 8035041 1 High And Third Shaft, Drum And Plug Assembly
24 8035042 1 Snap Ring, Retaining Thrust Washer
25 8035043 1 Bearing, Third Clutch Gear
26 8034924 1 Third Gear And Shaft
27 8035044 1 Bearing, Rear
28 8035045 3 Snap Ring, Retaining Rear Bearing
29 8035046 1 Bearing, Output Shaft
30 8035047 1 Snap Ring, Retaining Output Shaft Bearing
31 8035048 1 Plug, Capped End
32 8035049 1 O-Ring, Oil Seal Sleeve
KITS
33 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.46
OUTPUT SHAFT GROUP
(4 Speed)
9
11
3
4
10
7
3
6
4
7
5
3
2
1
8
12
3
PF0760
3.47
PS0101
3606 Rev 1/03
OUTPUT SHAFT GROUP
(4 Speed)
Item No. Part Number Qty. Description
1 8035056 1 Output Flange And Plug Assembly (Includes Item 2)
2 8035055 1 Plug, Flange
3 8035045 4 Snap Ring, Output Shaft Bearing And Plug
4 8035049 2 O-Ring, Oil Seal Sleeve And Plug
5 8035057 1 Seal, Oil - Output Shaft
6 8035058 1 Sleeve, Oil Seal
7 8035046 2 Bearing, Output Shaft
8 8035047 2 Ring, Retaining - Flange
9 8034929 1 Gear, Output Shaft
10 8035059 1 Shaft, Output
11 8035048 1 Plug, Output Shaft Bore
KITS
12 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.48
ELECTRIC CONTROL GROUP
(4 Speed)
2
3
4
5
6
7
8
16
15
14
13
12
11
10
9
1
29
PF0760
3.49
28
26
27
20
24
25
22
23
22
17
18
21
19
PS0110
3606 Origin 7/98
ELECTRIC CONTROL GROUP
(4 Speed)
Item No. Part Number Qty. Description
1 8035091 2 Modulation Valve Assembly (Includes Items 2 thru 16)
2 8035060 1 Housing, Modulator Valve
3 8035061 1 O-Ring, Modulator Housing
4 8035062 1 Pin, Stop
5 8035063 1 Spring, Inner
6 8035064 1 Spring, Middle
7 8035065 1 Pin, Upper
8 8035066 1 Pin, Lower
9 8035067 1 O-Ring, Sleeve
10 8035068 1 Sleeve, Modulator Housing
11 8035069 1 Spool, Regulator
12 8035070 1 Spring
13 8035071 1 Spacer, Spring
14 8035072 1 Retainer, Spring
15 8035073 1 Spool, Accumulator
16 8035074 1 Spring, Outer
17 8035075 2 Washer, Lock - Cover Screw
18 8035076 2 Screw, Cover
19 8035077 1 Cover, Protective
20 8035086 5 Spool Type Solenoid Cartridge Assembly (Includes Items 21 thru 24)
21 8035078 1 Retainer Nut, Valve Cartridge
22 8035079 2 O-Ring, Coil
23 8035080 1 Coil, Solenoid - 12 Volt
24 8035085 1 Cartridge, Valve - 4 Way (Includes Items 25 thru 28)
25 8035084 1 O-Ring, Cartridge
26 8035083 1 O-Ring, Cartridge
27 8035082 1 O-Ring, Cartridge
28 8035081 1 O-Ring, Cartridge
KITS
29 8035089 1 Transmission Gasket And Sealing Kit (Services Entire Transmission)
3606 Origin 7/98
3.50
WHEELS AND TIRES
Warning
!
Mis-Matched tire sizes, ply ratings or mixing of tire
types (Radial and Bias ply) may compromise
vehicle stability and may result in vehicle tipover.
1
Front Of Vehicle
5
3
2
6
4
8
7
3.51
PS0340
3606 Origin 7/98
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