Ford New Holland 5640, 6640, 7740, 7840, 8240, 8340 40 Series Tractor Service Manual 40564061 English
Brands: Ford / Ford New Holland / New Holland Agriculture
Equipment Type: Tractor
Manuals Type: Service Manual (Vol.1 + Vol.2)
Machine Model & Serial Number: 5640, 5640SL, 5640SLE, 6640, 6640SL, 6640SLE, 7740, 7740SL, 7740SLE, 7840, 7840SL, 7840SLE, 8240, 8240SL, 8240SLE, 8340, 8340SL, 8340SLE 40 Series
Region: N/R
Book Code: 40564061
Issued: N/R
Language: English
Pages: 1452
File Format: Portable Document Format (PDF)
Remark: This is the massive, 1452-page definitive factory service manual for the Ford New Holland 40 Series Powerstar Tractors. Selling Point & Notable Features: This manual is the ultimate technical authority, covering both standard SL and high-spec SLE models. It features extreme deep-level engine overhaul protocols (including cylinder block sleeving, boring, and honing), the complete diagnostic and repair sequence for the **Variable Displacement Closed Centre Load Sensing (CCLS) Hydraulic Pump**, and surgical teardown of the planetary rear axles. It provides non-negotiable precision data such as differential bearing pre-load shimming formulas and exact pressure-testing specifications. A monumental asset for professional workshops.
Table of contents
- FOREWORD & TRACTOR IDENTIFICATION
- Production Date Code Interpretation (Year, Month, Day, Shift)
- Component Serial Number Locations (Engine, Transmission, Rear Axle)
- Fuel Injection Pump Date Coding Logic
- PART 1 - ENGINE SYSTEM
- Chapter 1: DIESEL ENGINES (4 & 6 Cylinder Powerstar)
- Description and Operation
- Naturally Aspirated and Turbocharged Configuration Differences
- Engine Component Engineering (Cylinder Head, Valvetrain, Crankshaft)
- Lubrication System Flow and Rotor Pump Principles
- Fault Finding & Diagnostic Flowcharts
- Engine Overhaul Procedures
- Cylinder Head and Valvetrain
- Cylinder Head Flatness Verification (0.127mm limit)
- Valve Seat Refacing Angles (Intake 30°, Exhaust 45°)
- Valve Guide Boring, Reaming, and Bushing Replacement
- Valve Spring Squareness and Tension Testing
- Timing Gears and Engine Front Cover
- Crankshaft Timing Gear Heat Shrink Installation
- Timing Gear Backlash Tolerances (0.15-0.46mm)
- DPS Pump Timing Gear Alignment
- Cylinder Block, Pistons, and Connecting Rods
- Cylinder Block Sleeving - Detailed Boring and Honing Protocols
- Piston-to-Block Height Calculation (Compression Ratio Control)
- Piston Ring End Gap and Side Clearance Matrix
- Connecting Rod Alignment and Bearing Shell Fitting
- Crankshaft, Main Bearings, and Balancer
- Dynamic Balancer Phase Alignment (4-Cylinder Models)
- Crankshaft Journal Taper and Out-of-Round Measurement
- Plastigauge Method for Main Bearing Clearances
- Crankshaft End Play Shimming (0.10-0.20mm)
- Cylinder Head and Valvetrain
- Engine Compression Test Protocols
- Critical Fastener Torque Values and Specifications
- Description and Operation
- Chapter 2: COOLING SYSTEM
- Radiator and De-aeration Tank Overhaul
- Thermostat Bench Testing and Opening Temperatures
- Water Pump Disassembly (Impeller/Shaft/Seal Press Depth Specs)
- Viscous Fan Drive and Belt Tensioner Service
- Chapter 1: DIESEL ENGINES (4 & 6 Cylinder Powerstar)
- PART 2 - FUEL SYSTEM
- Chapter 1: FUEL SYSTEM - GENERAL
- DPS Fuel Injection Pump Adjustments (Idle and Max No-Load Speeds)
- Fuel System Priming and Bleeding Procedures
- Cold Start Thermostart System Operation
- Main and Auxiliary Fuel Tank Removal/Installation
- Chapter 2: AIR CLEANER (DRY & WET)
- Restriction Indicator Switch Calibration
- Dry Element Cleaning vs. Safety Element Replacement
- Aspirated Wet Pre-Cleaner Maintenance
- Chapter 1: FUEL SYSTEM - GENERAL
- PART 3 - ELECTRICAL SYSTEMS
- PART 4 - CLUTCHES
- PART 5 - TRANSMISSION SYSTEMS
- PART 6 - POWER TAKE-OFF (PTO)
- Two-Speed Non-Shiftable vs. Shiftable PTO Systems
- Drive Gear End Float Adjustment (Shimming Calculation Formula)
- PTO Clutch Assembly and Brake Pad Overhaul
- PTO Fault Finding and Pressure Specification Charts
- PART 7 - REAR AXLE AND BRAKES
- Chapter 1: REAR AXLE
- Planetary Final Reduction Overhaul (3 vs. 4 Gear Configurations)
- Differential and Electro-Hydraulic Differential Lock Service
- Axle Shaft Bearing Pre-load Adjustment (Spacer Selection Table)
- Differential Bearing Pre-Load Measurement (Special Tool FT.4501)
- Drive Pinion Bearing Pre-load and Stake Nut Adjustment
- Chapter 2: BRAKES
- Wet Disc Brake Operation and Hydraulic Actuation
- Master Cylinder and Slave Cylinder Surgical Overhaul
- Brake System Bleeding Sequence
- Transmission Handbrake Gear Backlash Calibration
- Chapter 1: REAR AXLE
- PART 8 - HYDRAULIC SYSTEMS
- Chapter 1: INTRODUCTION (CCLS vs. Fixed Displacement Logic)
- Chapter 2: VARIABLE DISPLACEMENT CCLS PUMP
- Theory of Swash Plate Control and Servo Piston Operation
- Load Sensing Calibration:
- Low Pressure Standby Pressure (21-24 bar)
- High Pressure Operating Control and Margin Pressure
- System Maximum Pressure Regulation (2800 lbf/in²)
- CCLS Pump Fault Finding Flowcharts
- Pump Overhaul: Disassembling Charge and Steering Pump Elements
- PART 9 - STEERING SYSTEMS
- PART 10 - FRONT AXLE (2WD & 4WD)
- PART 11 - CAB AND HVAC
- PART 12 - SEPARATING THE TRACTOR (Splitting Procedures)
Technical Insight
Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of the Ford 40 Series tractors. This 1,452-page manual provides critical instructions for fault finding, overhaul, and pressure testing across all 12 major parts. High-value technical data includes the calibration of the Variable Displacement Closed Centre Load Sensing (CCLS) hydraulic pump, rigorous cylinder block sleeving and boring tolerances, and the exact shimming formulas required for differential bearing pre-load using special tool FT.4501 to ensure drivetrain structural integrity under high-torque loads.