Complete Repair Service Technical Manual for John Deere 6145J, 6165J, 6180J & 6205J (Worldwide Edition), with all the shop information to maintain, repair, and rebuild like professional mechanics.

John Deere 2WD or MFWD Tractors 6145J, 6165J, 6180J & 6205J (Worldwide Edition)  workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM801519 Repair Technical Manual 6145J, 6165J, 6180J and 6205J Tractors / (Repair Only) (Diagnostic manual with electrical wiring diagrams sold separately)
TM801528 Repair Technical Manual Tracteurs 6145J, 6165J, 6180J et 6205J—Manuel technique de remise en état
TM801554 Repair Technical Manual Tratores 6145J, 6165J, 6180J e 6205J — Manual Técnico de Reparo
TM801563 Repair Technical Manual Tractores 6145J, 6165J, 6180J y 6205J — Manual técnico de reparación

PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English etc.

MAIN SECTONS
Foreword
   Safety
      Safety Regulations
   General Information
      Specifications
      Serial Numbers
      Adjusting
   Engine
      Removing and Installing Engine
      Removing and Installing Engine - 6205J Tractors
   Fuel Systems, Air Intake, Cooling and Exhaust
      Speed Control Link
      Fuel System
      Air Intake System
      Cooling System
      Exhaust System
   Electrical System
      Connectors
      Wiring Harnesses
      Charging Circuit
      Starter Motor Circuit
      Fuses, Relays and Switches
      Monitoring Systems
      Electrical Components
   Electronic Control Units
      General Information
      Removal and Installation of Electronic Control Units
   PowrQuad Transmission
      Removing and Installing PowrQuad Module
      Transmission Selectors Control
      PowrQuad Module
      Removing and Installing Range Box
      Range Box
   Drive Systems
      Removing and Installing Component
      U-Jointed Shafts and Torsional Damper
      Front-Wheel Drive Clutch - 6145J Tractor
      Front-Wheel Drive Clutch - 6165J, 6180J and 6205J Tractors
      Rear Differential - 6145J Tractor
      Rear Differential - 6165J, 6180J and 6205J Tractors
      Hydraulic Pump Drive
      Final Drives
      Rear PTO
   Steering and Brakes
      Hydrostatic Steering
      Steering - AutoTracAutoTrac is a trademark of Deere & Company
      Brake Valve
      Rear Wheel Brakes
      Air Brake System
   Hydraulic System
      Controls
      Oil Filters, Charge Pump and Hydraulic Pump
      Valve Block - 6145J Tractor
      Valve Block - 6165J, 6180J and 6205J Tractors
      Rockshaft
      Selective Control Valves and Couplers - 6145J Tractor
      Selective Control Valves and Couplers - 6165J, 6180J and 6205J Tractors
   Miscellaneous
      Removing and Installing Components
      Main Chassis
      Front Wheels, Rear Wheels and Fenders
      Center Link Bracket and Swinging Drawbar
   Operator`s Cab
      Removing and Installing Components
      Air Conditioning System
      Heating System
      Operator`s Cab
   Special Tools (Dealer-Fabricated)

TABLE OF CONTENTS
Section 05: Safety...25
  Group 05: Safety Regulations...1286
    Recognize Safety Information...468
    Follow Safety Instructions...28
    Replace Safety Signs...29
    Wear Protective Clothing...30
    Prevent Battery Explosions...31
    Service Tires Safely...32
    Keep ROPS Installed Properly...33
    Park Machine Safely...34
    Handle Fluids Safely—Avoid Fires...35
    Handle Fuel Safely—Avoid Fires...36
    Prepare for Emergencies...37
    Work in Clean Area...38
    Prevent Machine Runaway...39
    Work In Ventilated Area...40
    Avoid High-Pressure Fluids...41
    Use Proper Lifting Equipment...42
    Illuminate Work Area Safely...43
    Use Proper Tools...44
    Live With Safety...45
    Safety Measures on Electronic Control Units...46
Section 10: General Information...253
  Group 05: Specifications...1249
    Engine...51
    PTO...53
    Clutch Specifications...1249
    Transmission Specifications...1249
    Brakes Specifications...1249
    Hydraulic System...57
    Electrical System...59
    Tractor Weight in Standard Configuration...60
    Capacities...62
    Tire Combination Chart...64
    Dimensions...66
    Dimensions 6205J Tractor...68
    Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I...70
    Multipurpose Extreme Pressure (EP) Grease...72
    Transmission and Hydraulic Oil...73
    Front-Wheel Drive Axle Oil (Standard)...74
    Front-Wheel Drive Oil (3 Meters)...76
    Metric Bolt and Screw Torque Values...78
    Unified Inch Bolt and Screw Torque Values...80
    Hydraulic system inch fitting torques...82
    Hydraulic system metric fitting torques...83
  Group 10: Serial Numbers...47
    Interpreting the Serial Number of Your Machine - 17 digits PIN...86
    Year of Production Table (Digit 5)...87
    Transmission Type Table (Digit 6)...88
    Identification Numbers...89
    Tractor Identification Number...90
    Engine Serial Number...91
    PowrQuad™ Transmission Serial Number...92
    Differential Housing Serial Number...93
    Rear Final Drives Serial Numbers...94
    Front-Wheel Drive Serial Number—Dana...95
    Sub-Assembly Serial Numbers...96
  Group 15: Adjusting...48
    General Specifications - 6205J Tractors...98
    Using High-Pressure Washers...99
    Preliminary Engine Test...100
    Removing and Cleaning the Primary Air Cleaner Element...101
    Checking the Air Cleaner Safety Element...102
    Installing the Primary Filter Element...103
    Checking Air Intake System Connections for Leaks...104
    Checking the Crankcase Vent Hose for Clogging...106
    Cleaning Radiator Screen...107
    Checking Expansion Tank Cap...109
    Checking for Leaks in Radiator...110
    Checking Connections of Cooling System...111
    Checking Engine Thermostat...113
    Cleaning Water Separator...114
    Checking Fuel Filter...115
    Checking Fuel Injection Pump Adjustment...116
    Checking the Fuel Transfer Pump Operation - 6205J Tractors...117
    Cleaning Water Trap - 6205J Tractors...118
    Checking Fuel Filter - 6205J Tractors...119
    Bleed Fuel System - 6205J Tractors...208
    Checking Engine Speed Control Link Adjustment...182
    Cleaning Battery, Cables and Battery Box with a Clean Cloth...122
    Checking Neutral Start Circuit...123
    Checking Starter Motor...124
    Checking Lighting Circuit...125
    Final Engine Checks...126
    Tractor Operation Check...127
Section 20: Engine...128
  Group 00: Removing and Installing Engine...162
    Special Tools...1284
    Specifications...1249
    Removing Engine...150
    Installing Engine...162
  Group 05: Removing and Installing Engine - 6205J Tractors...128
    Specifications...1249
    Removing Engine...150
    Installing Engine...162
    Engine Mounting...169
    Replace the Engine Mountings...171
Section 30: Fuel Systems, Air Intake, Cooling and Exhaust...176
  Group 05: Speed Control Link...176
    Specifications...1249
    Other Material...1293
    Hand Throttle Lever and Accelerator Pedal Adjustment...188
    Speed Control Link Adjustment...182
    Hand Throttle Lever - Exploded View...183
    Accelerator Pedal, with Mechanical Speed Control...185
    Accelerator Pedal Adjustment...188
    Replace Accelerator Pedal Assembly - 6205J Tractors...189
    Remove Accelerator Pedal Potentiometer - 6205J Tractors...190
  Group 10: Fuel System...176
    General Information...253
    Specifications...1249
    Removing Fuel Tank...196
    Installing Fuel Tank...198
    Replacing Fuel Gauge Sensor Unit...199
    Replacing Fuel Transfer Pump...200
    Replacing Fuel Filter...201
    Bleeding Fuel System...202
    Fuel System - 6205J Tractor...204
    Replace the Fuel Transfer Pump - 6205J Tractor...206
    Changing the Fuel Filters - 6205J Tractors...207
    Bleed Fuel System - 6205J Tractors...208
  Group 15: Air Intake System...176
    General Information...253
    Air filter - Exploded view...211
    Replacing Air Filter Restriction Sensor...212
  Group 20: Cooling System...176
    General Information...253
    Specifications...1249
    Removing Radiator...216
    Installing Radiator...226
    Replacing Fan...227
    Removing and Installing the Expansion Tank...228
    Removing and Installing Thermostat...231
    Fill Cooling System with Coolant...232
    Fill Cooling System with Coolant - 6205J Tractors...235
    Remove and Install the Change Air Cooler...238
    Remove and Install the Charge Air Cooler - 6205J Tractors...240
    Releasing Drive Belt Tension...242
    Replacing Engine Fan Belt...243
    Replacing Drive Belt Tensioner...246
    Repairing Fan Console...247
    Remove and Install Fan Console (with Mechanical Coolant Pump)...249
    Remove and Install Oil Cooler...250
  Group 30: Exhaust System...177
    General Information...253
    Specifications...1249
    Muffler and Exhaust Pipe...255
Section 40: Electrical System...260
  Group 05: Connectors...294
    Special Tools...1284
    General...266
    Using high-pressure washers...267
    Disconnecting electrical circuits...432
    Reconditioning Wire Ends...269
    Installing a Terminal...270
    WEATHER PACK Connectors...294
    Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Rear Terminal Lock...260
    Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Front Terminal Lock...260
    Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connectors...294
    CAN BUS Terminating Resistor Connector...285
    Electronic Control Unit Connectors...294
    Connectors...294
    CRIMP SNAP IN Connectors...299
    KOSTAL Connectors...301
    DEUTSCH Connectors...304
    ITT Connector...308
    Individual Terminals...312
    Fuse and Relay Box — Open Station Tractors...314
    Fuse and Relay Boxes — Cab Tractors...317
  Group 10: Wiring Harnesses...260
    Disconnecting Electrical Circuits...469
    Wire Numbers and Color Codes...323
    Location of Ground Points...324
    Wiring Harness W01 — Power Supply...327
    Removing and Installing Wiring Harness W01 — Power link Box (6205J Tractors)...328
    Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Open Station Tractors)...329
    Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)...331
    Removing and Installing Wiring Harness W02 — Engine Wiring Harness (6205J Tractors)...333
    Wiring Harness W03 — Starter Relay...335
    Wiring Harness W04 — Headlights...336
    Wiring Harness W04 - Headlights - 6205J Tractors...337
    Removing and Installing Wiring Harness W05 — Battery Cables (except 6205J)...338
    Removing and Installing Wiring Harness W06 — Backup Alarm...340
    W06 — Backup Alarm Wiring Harness...341
    Removing and Installing Wiring Harness W08 — Open Station Tractors...342
    Removing and Installing Wiring Harness W08 — (Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated)...261
    Removing and Installing Wiring Harness W08 — (Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated)...261
    Removing and Installing Wiring Harness W09 — Console...348
    Removing and Installing Wiring Harness W09 — Console (6205J Tractors)...349
    Removing and Installing Wiring Harness W18 — Sun Canopy...351
    Removing and Installing Wiring Harness W19 — Cab Roof...352
    Removing and Installing Wiring Harness W20 — Loudspeakers...354
    W21 — Rear Wiper Switch Wiring Harness...355
    W22 — Rear Wiper Wiring Harness...356
    W23 — Rear Wiper Supply Wiring Harness...357
    Removing and Installing Wiring Harness W26 — Fan and Air Conditioning...358
    Removing and Installing Wiring Harness W28 — Front End of Transmission (Open Station Tractors)...359
    Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated)...261
    Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated...261
    Removing and Installing Wiring Harness W30 — Rear End of Transmission (Open Station Tractors)...364
    Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)...365
    Wiring Harness W31 — Power Take-Off for 7-Pin Socket...366
    Removing and Installing Wiring Harness W43 — GreenStar™ Roof Wiring Harness...367
    Removing and Installing Wiring Harness W44 — GreenStar™ Display Wiring Harness...368
    Removing and Installing Wiring Harness W45 — AutoTrac™ SBBC Wiring Harness...369
    Removing and Installing Wiring Harness W46 — Steering Wheel Position Wiring Harness...371
    Removing and Installing Wiring Harness W47 — GreenStar™ Display Wiring Harness...372
    Removing and Installing Wiring Harness W49 — Implement CAN Bus Wiring Harness...373
    Removing and Installing Wiring Harness W94 — Wheel Angle Sensor Wiring Harness (Standard Front Axle)...374
    Removing and Installing Wiring Harness W94 — Wheel Angle Sensor Wiring Harness (3 Meters Front Axle)...375
  Group 15: Charging Circuit...262
    Special Tools...1284
    Specifications...1249
    Repairing the Alternator...379
    Disconnecting Electrical Circuits...469
    Removing/Installing Alternator...381
    Removing/Installing Alternator Pulley...383
  Group 20: Starter Motor Circuit...262
    Specifications...1249
    Repairing the Starting Motor...387
    Disconnecting Electrical Circuits...469
    Removing and Installing Starter Motor...389
  Group 25: Fuses, Relays and Switches...262
    Note...437
    Special Tools...1284
    Specifications...1249
    Removing Hood Covers...394
    Disconnecting Electrical Circuits...469
    Fuses—Junction Box...398
    Fuse and Relay Box—Open Station Tractors...399
    Fuse and Relay Box—Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated...262
    Fuse and Relay Box—Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated...262
    Fuses and relays (Power Link Box)...410
    Power Link Box- Components...411
    Replacing Starter Motor Relay...412
    Replacing Starter Motor Relay - 6205J Tractors...414
    Replacing Starter Switch...416
    Replacing Brake Switches...417
    Replacing Light Switch...418
    Replacing Full/Low Beam Switch...419
    Replacing Work Light Switches...420
    Replacing Hazard Warning Light Switch...421
    Replacing Turn Signal Switch...422
    Replacing Horn Switch...423
    Replacing Windshield Wiper and Windshield Washer Switch...424
    Replacing Front-Wheel Drive Switch...425
    Replacing Fan Switch...426
    Replacing Differential Lock Switch...427
    Replacing Rockshaft Remote Control Switch...428
  Group 30: Monitoring Systems...263
    Note...437
    Note...437
    Disconnecting electrical circuits...432
    Replacing Engine Speed Sensor Unit (B01)...433
    Replacing Engine Oil Pressure Sensor Unit (B04)...434
    Replacing Coolant Temperature Gauge Sensor Unit (B08)...435
  Group 40: Electrical Components...263
    Note...437
    Special Tools...1284
    Specifications...1249
    Disconnecting Electrical Circuits...469
    Replacing Socket of 7-Terminal Power Outlet...441
    Replacing Service Socket...443
    Removing Windshield Wiper Motor...445
    Removing Windshield Washer Pump...447
    Adjusting the Headlights...448
    Adjusting Cab Frame Lights...450
    Lights with Halogen Bulbs...452
Section 45: Electronic Control Units...454
  Group 05: General Information...253
    Special Tools...1284
    Control Unit Locations...457
    Control Unit Functions...460
  Group 10: Removal and Installation of Electronic Control Units...454
    General Information on How to Reprogram Control Units...464
    Check and Download Tractor-Specific Software Information...465
    Instructions when Replacing a Control Unit...466
    Instructions when Replacing a VIN Control Unit...467
    Safety Information...468
    Disconnecting Electrical Circuits...469
    Replacing BCU Control Unit...470
    Replacing TECU Control Unit...475
    Replacing SBBC Control Unit...477
    Replace ECU Control Unit...479
    Terminating Resistors for the CAN BUS (Cab)...480
Section 55: PowrQuad Transmission...482
  Group 00: Removing and Installing PowrQuad Module...482
    Special Tools...1284
    Specifications...1249
    Removing PowrQuad Housing...488
    Installing PowrQuad Housing...492
  Group 05: Transmission Selectors Control...482
    Specifications...1249
    Reconditioning of Gearshift, Park Brake, and Forward/Reverse Mechanism...497
    Reconditioning of Range-Shift Mechanism...501
    Adjust Gear-Shift and Range-Shift Cables...504
    Adjusting Forward/Reverse Cable...506
    Adjusting Cable and Stop Screw Park Break...508
    Adjusting Clutch Pedal...509
  Group 10: PowrQuad Module...482
    Special Tools...1284
    Other Material...1293
    Specifications...1249
    Transmission Components...518
    Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)...519
    Removing and Installing Oil Filter Base...520
    Replacing Oil Filter...521
    Removing and Installing Front Valve Housing...522
    Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)...525
    Removing and Installing Transmission Front Cover...539
    Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)...541
    Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)...546
    Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)...552
    Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)...555
    Removing Transmission Oil Pump...559
    Servicing Transmission Oil Pump...561
    Installing Transmission Oil Pump...568
    Removing Planetary Drive Gears...569
    Repairing Planetary Drive Gears...571
    Installing Planetary Drive Gears...578
    Removing B1 Brake Housing...584
    Reconditioning B1 Brake...585
    Installing B1 Brake Housing...587
    Removing B2-B3 Brake Housing...588
    Reconditioning B2 Brake...589
    Reconditioning B3 Brake...591
    Installing B2-B3 Brake Housing...594
    Removing C4 Clutch...595
    Reconditioning C4 Clutch...596
    Installing C4 Clutch...607
    Removing Reverse Brake...608
    Servicing Reverse Brake...609
    Installing Reverse Brake...612
    Removing Forward Clutch with Planetary Drive (Forward/Reverse)...613
    Servicing Forward Clutch with Planetary Drive (Forward/Reverse)...614
    Installing Forward Clutch with Planetary Drive (Forward/Reverse)...628
    Replacing Output Shaft...630
  Group 15: Removing and Installing Range Box...638
    Special Tools...1284
    Specifications...1249
    Removing Range Box...635
    Installing Range Box...638
    Final installation...640
  Group 20: Range Box...483
    Special Tools...1284
    Other Material...1293
    Specifications...1249
    Cross-Sectional View—Range Box...645
    Input Shaft—Exploded View...647
    Remove Input Shaft...648
    Repair Input Shaft...650
    Install Input Shaft...654
    Adjust Input Shaft End Play...656
    Output Shaft—Exploded View...658
    Remove Output Shaft...660
    Output Shaft Installation and Pre-Charge Pinion Adjustment...664
    Adjust Output Shaft End Play...670
    Remove, Repair, and Install Shift Cover...672
    Repair Shifting Mechanism...674
    Repair Park Lock...676
    Adjust Range Shift...678
    Replace Ground Speed Sensor...679
Section 56: Drive Systems...681
  Group 00: Removing and Installing Component...681
    Special Tools...1284
    Specifications...1249
    Removing MFWD Clutch...688
    Installing MFWD Clutch...691
    Removing Differential Housing...692
    Installing Differential Housing...700
    Removing Final Drive...704
    Installing Final Drive...709
    Removing Rear PTO...712
    Installing Rear PTO...715
  Group 05: U-Jointed Shafts and Torsional Damper...681
    Special Tools...1284
    Use of Special Tool KJD10426...719
    Specifications...1249
    Removing MFWD Universal-Joint Drive Shaft...721
    Repairing MFWD Universal-Joint Drive Shaft...722
    Installing MFWD Universal-Joint Drive Shaft...726
    Removing Engine Universal-Joint Drive Shaft...728
    Removing Torsional Damper...729
    Replacing Torsional Damper Bearings...730
    Installing Torsional Damper...731
    Installing Engine Universal-Joint Drive Shaft...733
  Group 10: Front-Wheel Drive Clutch - 6145J Tractor...681
    Special Tools...1284
    Specifications...1249
    MFWD Clutch Repair Instructions...754
    MFWD Clutch — Cross-Sectional View...755
    Disassembling MFWD Clutch...757
    Disassembling MFWD Clutch Assembly...759
    Mounting MFWD Clutch Assembly...763
    Mounting MFWD Clutch...767
  Group 11: Front-Wheel Drive Clutch - 6165J, 6180J and 6205J Tractors...682
    Special Tools...1284
    Specifications...1249
    MFWD Clutch Repair Instructions...754
    MFWD Clutch — Cross-Sectional View...755
    Disassembling MFWD Clutch...757
    Disassembling MFWD Clutch Assembly...759
    MFWD Clutch Exploded View...761
    Mounting MFWD Clutch Assembly...763
    Mounting MFWD Clutch...767
  Group 15: Rear Differential - 6145J Tractor...682
    Special Tools...1284
    Specifications...1249
    Rear Differential Repair Instructions...799
    Rear Differential — Cross Sectional View...801
    Removing Rear Differential...803
    Disassembling Rear Differential...806
    Rear Differential — Exploded View...811
    Assembling Rear Differential...813
    Adjust Rear Differential Preload...819
    Adjust Rear Differential Backlash...821
    Installing Rear Differential...823
  Group 16: Rear Differential - 6165J, 6180J and 6205J Tractors...682
    Special Tools...1284
    Specifications...1249
    Rear Differential Repair Instructions...799
    Rear Differential — Cross Sectional View...801
    Removing Rear Differential...803
    Disassembling Rear Differential...806
    Rear Differential — Exploded View...811
    Assembling Rear Differential...813
    Adjust Rear Differential Preload...819
    Adjust Rear Differential Backlash...821
    Installing Rear Differential...823
  Group 20: Hydraulic Pump Drive...683
    Special Tools...1284
    Specifications...1249
    Removing and Disassembling Pump Drive Pinion...827
    Removing and Disassembling Pump Drive Gear...830
    Assembling and Installing Pump Drive Gear...832
    Assembling and Installing Pump Drive Pinion...835
    Checking and Adjusting Play of Pump Drive Pinion...838
  Group 25: Final Drives...683
    Special Tools...1284
    Specifications...1249
    Final Drive Repair Instructions...842
    Final Drive Housing — Cross Sectional View...844
    Final Drive Housing — Exploded View...845
    Removing Planetary Carrier...847
    Disassembling Planetary Carrier...849
    Planetary Carrier — Exploded View...851
    Assembling Planetary Carrier...852
    Removing Final Drive Housing to Axle...854
    Disassembling and Assembling Final Drive Housing...856
    Disassembling and Assembling Axle...857
    Installing Final Drive Housing to Axle...859
    Installing Planetary Carrier...860
    Measuring Rolling Drag...862
    Checking Final Drive Shaft and Retainer...867
    Final Assembly...967
  Group 30: Rear PTO...53
    Special Tools...1284
    Specifications...1249
    Replacing Output Shaft Seal Ring...873
    Rear PTO Clutch - Cross Sectional View...874
    Rear PTO Clutch - Exploded View...876
    Removing Rear PTO Clutch...878
    Reconditioning Rear PTO Clutch...881
    Reconditioning Rear PTO Brake...890
    Installing Rear PTO Clutch...891
    Rear PTO Drive Train - Cross Sectional View...894
    Rear PTO Drive Train - Exploded View...895
    Removing Rear PTO Drive Train...898
    Reconditioning Output Shaft...902
    Reconditioning Countershaft...907
    Installing Rear PTO Drive Train...909
    Adjust Taper Roller Bearing of Countershaft...910
    Adjust Tapered Roller Bearing of Bearing Support...912
    Reconditioning Rear PTO Solenoid Valve...915
    Reconditioning Rear PTO Modulating Valve...917
    Replacing Rear PTO Speed Sensor...920
    Reconditioning Oil Sight-Glass...921
Section 60: Steering and Brakes...924
  Group 05: Hydrostatic Steering...924
    Special Tools...1284
    Preliminary Work...956
    Disconnecting/Connecting Steering or Brake Hoses...929
    Removing Steering Valve...931
    Steering - Exploded View...934
    Steering Column - Exploded View...936
    Steering With AutoTrac AutoTrac is a trademark of Deere & Company Integrated...924
    Installing Steering Valve...939
  Group 10: Steering - AutoTracAutoTrac is a trademark of Deere & Company...924
    Specifications...1249
    AutoTrac™ Integrated—Components...944
    Replacing the Steering Control...945
    Replace Solenoid Valves...948
    Replacing the Steering Wheel Position Sensor...950
    Replacing the Wheel Angle Sensor...951
  Group 15: Brake Valve...924
    Special Tools...1284
    Specifications...1249
    Brake Valve Repair Instructions...955
    Preliminary Work...956
    Remove and Install Brake Valve...957
    Disassembling Brake Valve...959
    Installing Brake Valve...964
    Adjusting Brake Pedals...965
    Adjusting Brake Switches...966
    Final Assembly...967
  Group 20: Rear Wheel Brakes...924
    Special Tools...1284
    Specifications...1249
    Rear Wheel Brakes - Exploded View...973
    Removing Rear Brakes...974
    Reconditioning Rear Brakes...976
    Installing Rear Brakes...978
    Replacing Retraction Pins on the Rear Wheel Brakes...980
    Bleeding Brakes without Air Brakes...983
    Bleeding Brakes with Air Brakes...985
  Group 25: Air Brake System...925
    Special Tools...1284
    Specifications...1249
    Air Brake System Repair Instructions...990
    Screw Union Installation...991
    Changing Compressor...993
    Changing Compressor Gaskets...994
    Changing Compressed Air Tank...996
    Changing Pressure Control Valve...998
    Changing Trailer Control Valve (Dual-Line Brakes)...999
    Changing Coupling Ends...1000
    Test Sequence...1001
    Checking System for Leaks...1002
    Checking Supply Coupling End...1003
    Checking Dual-Line Brakes...1004
    Adjusting Handbrake (Air Brake System)...1006
Section 70: Hydraulic System...1007
  Group 05: Controls...1007
    Specifications...1249
    Selective Control Valves — Removing and Installing Actuating Elements...1012
    Selective Control Valves — Adjusting Bowden Cable...1016
  Group 10: Oil Filters, Charge Pump and Hydraulic Pump...1007
    Specifications...1249
    Removing and Installing Hydraulic Oil Mesh Filter...1019
    Removing and Installing Hydraulic Oil Filter...1022
    Charge Pump - Exploded View...1026
    Removing and Installing Charge Pump...1029
    Charge Pump - Checking the Lube Oil Valve...1033
    Hydraulic Oil Reservoir — Restrictor...1034
    Hydraulic Pump - Removing and Installing Pressure-and-Flow Controller...1035
    Hydraulic Pump - Reconditioning Pressure-and-Flow Controller...1037
    Removing and Installing Hydraulic Pump...1039
    Hydraulic Pump - Exploded View...1044
    Disassembling Hydraulic Pump...1046
    Assembling Hydraulic Pump...1047
  Group 15: Valve Block - 6145J Tractor...1007
    Special Tools...1284
    Specifications...1249
    Hydraulic System Repair Instructions...1086
    Rockshaft Direct Control...1060
    Removing and Installing Rockshaft Valve Spacer...1061
    Removing Rockshaft Valve...1088
    Rocksaft Valve - Exploded View...1065
    Repairing Rockshaft Valve...1067
    Installing Rockshaft Valve...1070
    Rockshaft Valve — Depth of Raising and Lowering Valves...1072
    Rockshaft Valve — Removing and Installing Stepper Motor...1073
    Rockshaft Valve — Centering Stepper Motor...1075
    Removing Priority Valve...1076
    Priority Valve - Exploded View...1078
    Repairing Priority Valve...1080
  Group 16: Valve Block - 6165J, 6180J and 6205J Tractors...1008
    Special Tools...1284
    Specifications...1249
    Hydraulic System Repair Instructions...1086
    Removing Rockshaft Valve...1088
    Rockshaft Valve - Exploded View...1090
    Reconditioning Rockshaft Valve...1092
    Installing Rochshaft Valve...1095
    Rockshaft Valve - Removing and Installing Stepper Motor...1098
    Removing Priority 1 Control Block...1100
    Install Priority 1 Control Block...1101
    Reconditioning Priority 1 Control Block...1102
    Removing Priority 3 Control Block...1105
    Installing Priority 3 Control Block...1109
    Recondition Priority 3 Control Block...1113
  Group 20: Rockshaft...1008
    Other Material...1293
    Specifications...1249
    Rockshaft - Removg and Installing Position Sensor and Toothed Segment...1119
    Rockshaft - Removing and Installing Rockshaft...1123
    Rockshaft - Removing and Installing Bearing Support...1128
    Rockshaft - Removing Rockshaft Cylinders...1130
    Rockshaft - Reconditioning Lift Cylinder...1131
    Rockshaft - Installing Rockshaft Cylinders...1134
    Rockshaft - Removing and Installing Draft Load Potentiometer and Draft Link Support...1135
  Group 25: Selective Control Valves and Couplers - 6145J Tractor...1008
    Special Tools...1284
    Specifications...1249
    Selective Control Valves (SCVs) and Couplers Repair Instructions...1174
    Removing and Installing Shuttle Valves...1145
    Removing Selective Control Valves...1146
    Disassembling, Inspecting and Assembling 100 Series Selective Control Valve...1147
    Disassembling, Inspecting and Assembling 300 Series Selective Control Valve...1153
    Installing Selective Control Valves...1164
    Adjusting Pressure with Selective Control Valves...1167
    Quick Couplers — Service...1168
    Mounting Quick Coupler...1170
  Group 26: Selective Control Valves and Couplers - 6165J, 6180J and 6205J Tractors...1009
    Special Tools...1284
    Specifications...1249
    Selective Control Valves (SCVs) and Couplers Repair Instructions...1174
    Remove the Selective Control Valves (SCVs)...1176
    Recondition the Selective Control Valves (M-SCVs 100)...1178
    Recondition the Selective Control Valves (M-SCVs 300)...1182
    Recondition the Selective Control Valves (M-SCVs 450)...1185
    Install the Selective Control Valves (SCVs)...1188
    Selective Control Valves (SCVs) - Reconditioning the Couplers...1193
Section 80: Miscellaneous...1195
  Group 00: Removing and Installing Components...1195
    Special Tools...1284
    Specifications...1249
    Removing Main Chassis...1199
    Installing Main Chassis...1204
    Removing Front-Wheel Drive Axle...1207
    Installing Front-Wheel Drive Axle...1210
  Group 05: Main Chassis...1195
    Specifications...1249
    Reconditioning Main Chassis...1214
  Group 15: Front Wheels, Rear Wheels and Fenders...1195
    Special Tools...1284
    Specifications...1249
    Installing Front Fenders...1218
    Removing Front and Rear Wheels...1221
    Reconditioning Front and Rear Wheels...1223
    Install Front and Rear Wheels...1226
    Service Heavy-Duty Wheel Clamps...1230
  Group 20: Center Link Bracket and Swinging Drawbar...1241
    Specifications...1249
    Check Swinging Drawbar Wear...1238
    Installing Center Link Bracket...1240
    Swinging Drawbar...1241
    Adjust Hammer Strap...1243
    Drawbar With Ball Pin...1244
Section 90: Operator's Cab...1245
  Group 00: Removing and Installing Components...1245
    Special Tools...1284
    Specifications...1249
    Swinging Up Operator's Cab...1250
    Swinging Down Operator's Cab...1267
    Removing Operator's Cab or Platform...1270
    Installing Operator's Cab or Platform...1278
    Checking and Adjusting Gear Shift Units...1282
  Group 15: Air Conditioning System...1245
    Special Tools...1284
    Tightening Torque for Refrigerant Hoses...1285
    Safety Regulations...1286
    Handling Refrigerant...1287
    In the Event of an Emergency...1288
    Safety Equipment...1289
    Storage of Refrigerant Containers...1290
    Refrigerant R134a...1291
    Important...1292
    Other Material...1293
    Specification...1294
    Filling the Cylinder...1295
    Charging Air Conditioning System (With Loading Cylinder)...1297
    Charging Air Conditioning System (With Recovery/Recycling and Charging Station)...1299
    Adding Oil to the Air Conditioning System...1300
    Leak Test...1302
    Evacuate Air Conditioning System...1303
    Cleaning the Air Conditioning System...1305
    Separating Compressor...1306
    Check Refrigerant Oil Level...1307
    Disassembling Compressor Clutch...1308
    Checking Clutch Hub Separation...1311
    Install Compressor...1312
    Separating and Installing Condenser...1313
    Separating and Installing Drier...1314
    Replacing Expansion Valve...1315
    Separating and Installing Evaporator and Expansion Valve...1316
    Installing Condensation Water Drain Hoses...1318
    Layout of Condensation Water Drain Hoses...1319
    Separating and Installing Thermostat...1320
    Separating and Installing High/Low Pressure Switch...1321
    Vacuum Pump — General Information...1322
  Group 20: Heating System...1246
    Fan and Heater, Disassembling...1325
    Removing Cab Air Filter...1327
    Separating and Installing Fan...1329
    Separating and Installing Heater Regulator...1330
    Separating Heater/Evaporator Housing...1331
  Group 25: Operator's Cab...1246
    Removing Cab Frame...1334
    Cab Mounting Torques...1335
    Removing and Installing Windshield...1337
    Remove and Install Rear Window...1339
    Installing Door Lock...1341
    Adjusting Window Contact Pressure...1343
    Removing and Installing Operator's Cab Door...1344
    Removing and Installing Sun-Visor Roller...1346
    Remove and Install Operator’s Seat...1347
Section 99: Special Tools (Dealer-Fabricated)...1349
  Group 05: Special Tools (Dealer-Fabricated)...1349
    DFLX1 - Adapter Strut...1351
    DFLX7 - Turning Device...1366
    DFLX14 – Suspended MFWD Axle Housing Bracket...1353
    DFLX29 - Support...1354
    DFLX42 - Turning Device...1366
    Lifting Device...1356
    Holding Device...1357
    Suspension Eyes for Operator's Cab...1358
    Holding Tool...1359
    Wooden Block...1360
    DFRW79 - Piston Holding Tool...1361
    Socket Wrench Insert...1369
    Seal Installer...1367
    Driver...1364
    Assembly and Guide Mandrels...1365
    Turning Device...1366
    Seal Installer...1367
    JDG10198 Terminal Crimping Tool...1368
    Socket Wrench Insert...1369
    Special Wrench...1370
    Electrical Repair Tool Kit...1371
    Quick Coupler Securing Support...1372
    Lifting Tool...1373

John Deere Tractors 6145J, 6165J, 6180J, 6205J Repair Technical Manual (TM801519)