Professional Documents
Culture Documents
SPECIAL TOOLS
CONTENTS
NOTE: Order tools from your SERVICE GARD Catalog, unless otherwise indicated.
PURCHASED TOOLS
2364 ... ...... 99-01 JDE-35 JDG29O
cs-2428 JDE-37A JDG292. 99-25
D-010034A JDE-55 JDG293
D-01045AA ... 99-02 JDE-66 . ......99-14 JDG295
D-01049AA JDE-78-1 JDG298 .., 99-26
D-01061AA JDE-78-2 JDG299
D-01062AA 99-03 JDE-78-16 JDG3O2
D-01 109AA 99-04 JDE-79 . ...... 99-15 JDG303
D-01 1 1 0AA JDE-80 JDG304 99-27
D-01 1 1 4AA JDE-81-1 JDG3O5
D-01 1684A JDE-81-4 JDG306
D-01 173AA ... 99-05 JDE-90 . ...... 99-16 JDG3O7
D-012064A JDE.92 JDG3O8. 99-28
D-01219AA ... 99-06 JDE.93 JDG311
D-05007sT JDE-96 JDG312
D-05029ST 99-0 7 JDE-99 . ...... 99-17 JDG313
D-05058ST JDE.105 JDG315 . 99-29
D-05103ST 99-08 JDE.1O64 JDG317
D-05104ST JDE-41296 99-'r 8 JDG337
D-05124ST JDF.29 JDG400-7
D-05155ST ... 99-09 JDF-33. 99-19 JDG523. 99-30
D-05267ST JDG-10-2 JDG524
D-05314ST JDG-15 JDG-570
D-15001NU ... 99-10 JDG-164 JDG.581
D-15038NU JDG-17 . ...... 99-20 JDH-15C 99-31
D-15041NU 99-104 JDG.18 JDH-28
D-170048R JDG-19 JDH-314
D-1701 1 BFt JDG-23 JDH.35A
D-170158R JDG-24 . ......99-21 JDH-42-1
D-170248R 99-108 JDG-74-1 JDH-42-2 99-32
D-170308R JDG-127 JDH-52
D-17501C1 JDG-138 JDH-57
D-17515C1 ... 99-11 JDG-138-2 .... 9S-22 JDST-29
D-17525C1 JU\jZ IC JDT-1 ,.
D-17526C1 JDG236 JDT-3A
D-18009KD JDG239 . ..... 99-23 J DT.'I O
D-18019KD ... 99-12 JDG246 JDT-23
D-19001TT .. 99- 12A JDG247 JDT-244 99-34
D-20002w1 99-128 JDG249 JDT-26
JD3O6-A JDG266 . ..... 99-24 JDT-30
JDE.3 JDG268 JDT-31
JDE-6 JDG287
JDE-7.. ....,. 99-13 JDG289
Contlnued on Dext page
99Uj099C0N r61087
CONTENTS-Continued
PURCHASED TOOLS-Continued FABRICATED TOOLS
JDT-32 .. . Adapter, Housing ......... 99-39 Lift Tool, Planetary 99-48
JDT.38 Compressor, Shock Absorber Lift Tool, Fockshafi . . . . . . . 99-49
JDr-42 Spring .. ..... 99-40 Puller, Tube and Sleeve ... 99-50
JDT-46 .. , Starting Motor Commutator Removal Tool, Trans. lnput Shalt
JT01463 Bushing Too1 .......... 99-41 Set, l,4odified D-05001ST .. 99-51
JT01633 Extension, Rockshaft, Arm . . 99-42 Spanner. 99-52
JT03296 Holding Fixture, Cylinder Stop, Pivot
JT05470 99-37 Lrner.... .....99-43 Wrench, Spanner 99-53
JT05746 Holding Fixture, Turbocharger Removal/Tool, Final Drive
JT27701 99-3 8 Turbine . ..... 99-44 Gear.... ....99-54
JT27702 Holding Tool, DDS Shaft, PTO Gear End Play
JT27706 Holding Tool, Yoke . ...... 99-45 Adjusting ..... 99-54
Jr27707 99-384 Hook, Planetary Fitting, N,,lFWD Pivot Pin
oTC 33858 Jacking Tool, Axle .. . . .... 99-46 Adatper . ..... 99-55
TY1481 .. 99-38 B Lifting Tool, Differential ... Sg-47 Holding Tool, SCV
TY-3315 Coupler . .... 99-56
!eLr,ireec0N a r6Lrar
__]
2364
cs-2428
The ne wrench s used to loosen and tighten injection pump
f!ei line connectors.
D-0't 003AA
D.01049A4
These 13-Ton puller set tools are used to remove and install
bearings and bearing cups.
D-01061AA
The blind hole puller is used to remove steering motor
feedback piston bushings.
D-o't 110AA
D-01114AA
'r$
D-01168AA
The spring compression tester is used to measure springs.
D-01 173AA
The 17 12 ton puller set tools are used to remove and Install
bcarings and bealng cups.
D-01206AA
The pul er (A) rs used w th No. 630-6 Step piate Adapter (B) n G)
to remcve damper pulley.
I 1
$xwW
I
rc
J
D-05007sT
#"
d$s #p
li'
D-05058ST
D-05103ST
D-05104ST
D-05124ST
':
l:i l
D-05267ST
D-05314ST
D-15038NU
{- o i*#,..:
:J#f**'.,u"\,
S*s
A-
NO. DESCRIPTION *re
2632 3/4 Tube rvlth l/4 Tee
B - 2633 Tubc Test Plug
c - 2634 UA b 1A Tube Ad.pter
D - 2635 7/8 to 7/16 Ad8pter
E - 2636 Unlon Adaptor Aaaembly
F - 2637 Tube Adapter F' L, 6,n
G - 6887
H - 6888
5/8 to 7/16 Reducer
3/4 to 7/16 Reducsr
tl'rfl-t\*- Y.
| - 7432 3/4 to sla Rsducar Elbow
J - 7436
K - 7426
1/2 to 7116 Reducet
112lo 7116 Roducor Elbow ) Y*"O ":1"',"$'
L - 7427 7/16 to 5.8 Ad.pter
M.7439 7/16 to 5/8 Roducsr
N- 7 447 Cap (2 used)
o - 7509 7/8 to 7 / 16 Adaptel
P - 7510 7/8 to 7/16 Reducel I
Q . 7511
R80l96At
314 lo 7116 Tee Aslsmbly
D-170048R
The flex hone is used to hone cylinder liners.
D-17015BR
R 274751i
U.S.A. 99-10A
D-'t 7024BR
D- t 703088
D-17501C1
The outside mjcrometer is used to measure and inspect
parts.
fr*
The dial calipers is used to measure and inspect parts.
f
D-'t 7525C1
D-17526C1
D-18009KD
D-20002w1
JD3O6-A
JDE.3
The driver is used to install tront crankshaft wear sleeve.
JDE.6
The shaft and mandrels are used to remove and install
camshaft bushings.'
k:L:irlii
'The JDG,1O5 Camshalt Bushng Replacement Set can also be used.
A76;R26r49 !r r'99aa
JDE-35
r2?6A8
JDE-37A
The torque wrench adapter is used retorque cylinder
head
cap Screws after run-in.
RG2605
JDE.55
The ring groove wear gauge is used to check keystone
ring
grooves.
Lrtho in U.S.A.
The replacement nng rs used wrth JDE-7 Driver to install
intake valve seat inserts.
JDE-78-1
JDE-78-2
The gauge bar rs used with JDE-78-6 forcrng screw to adjust
PER t\,4A-CLUTCH.
JDE-78-16
JDE-80
JDE-81-1
JDE-81-4
The timing pin is used to locate timing hole in flywheel when
timing the engine.
TN4.1258 (Dec-93)
JDE-90
JDE-92
::!taa2l;
JDE-93
JDE.96
The ring compressor is used to compress piston rings while
installing piston.
JDE-99
':"i1 __l
_l
JDE-105
e--
The nozzle cleaning kit is used to clean injection nozzles.
B-Pin Vise
C-Sac Hole Cleaning Drill
D-Cleaning Needtes
E-lnspection tvlagnif ier
JDE-106A
The JDE-106-4 Toot Set (A) is used with No.27489 Driver
(B) to install crankshaft rear wear sleeve and rear
oii seal.
JDF.5
T56 358i'l
A-JDF-9-1A Wrench*
B-JDF-9-2A Screwdriver*
These tools are used to adjust fast idle speeds on Robert
@---,9
Bosch injection pumps.
-Part of the JDF-gA Fast ldle Stoo Screw Wrench Kit
@-4
JDF-29
The retaining ring point set is used with the JDG-24 snap
ring plier kit to remove and install snap rings in Schwitzer
turbochargers.
TM-1258 (Dec-83)
JDF-33
The farst idle adjustment socket is used to adjust the fast idle
speed on Nippondenso injection pumps.
JDG-10-2
JDG-15
JDG-16A
JDG-18
JDG-19
JDG-23
The litt sling is used to support engine during removal.
JDG-74-1
A-Shaft
B-rOG.294 cauge Legs
JDG.127
The O-ring Seal tool set is used to aid in removing and
installing turbine shaft piston rings in the turbochargJr.
JDG-138-1
JDG236
The seal inslaller is used to install the inner seal in the axle
housrng.
\..r. ! , ::.'jr '.i
ri, ..
l-'
JDG239
t,;;
The pu ler is used to remove the steering motor feedback
l
piston sleeves
I JDG247
The test kit is used to test air condrtioning systems.
a-7 / 16-20 (F) x 7/16-20 (M) 90.
B-7/16-20 (M) x 7/16-20 (M) Srraight
C-3/8-24 lM) x 7/ t6-20 {M) Straight
D-3/8-24 lM) x 7/16-20 (M) Straighr
E-3/8-24 (M) x 7/16-20 (Nt) 90.
(F) Female '.:,/
(N,4) N4ale
All fittings are 45' f lare
JDG249
JDG268
JDG287
,f,s
JDG289
TM-'1354
99LJrJDG239 130935
JDG29O
JDG292
JDG293
JDG295
r'.'
The pinion gage set is used to determine drive pinionto-
bevel pinion contact.
JDG299
The king pin puller set is used to remove knuckle king pins.
JDG302
JDG303
The bearing cup installer set is used to install both the front
and rear differential drive shaft bearing cups in the transmis_
sron case simultaneously.
A-rOG344 Adapter
(uBed on 4050-4250.4450)
B-JDG345 Adapter
(used on 4650-4850)
C-JDG346 Adapter
(uEed on all models)
D-9crew
JDG305
JDG306
JDG307
JDG311
JDG312
JDG313
JDGs17
JDG337*
"ffi
The connecting rod bushing service set, is used to remove
and Install piston pin bushings in the 6466T Engine connecf
ing rods.
JDG400-7
JDG524
I
JDG57O
A-JOG574 Collet
B-jDG572 Tube
C--JDG571 Plate
IFJDG573 Forclng Scrsw
ACl;RUr1226 I 99J 0r. rLraf
/ fr"
A----.JUUCdZ Flecetver UUO
B-JDG583 Forcing Screw, 8mm with washer and nut
p
C-JDG584 Forcing Screw, 1O mm with washer and nut
D--JDG585 Cross Leg Adapters
E--JDG586 C-Rin9 lnsert
-
acrRr.r,/ L - rG55r r/-r!
Litho in U.S.A.
TlVl-1354 (Sep-87)
Special Tools
JDH-15C
JDH.28
The valve seat driver is used to install the rockshaft control
valve quides.
JDH-31.A
The seal driver is used to install main pump shaft oil seal.
JDH.35A
The seal puller is used to remove main pump shaft oil seal.
JDH-42-1
JDH-42-2
The alignment dowels (B) are
metering pump.
JDH-52
P 215 7 Lri
[;';
The slee're removal tool is used to remove the sleeve lrom
the HYDFACUSHIONED seat requlating vatve housing.
. ]]LI:
JDST-29
JDT^ ! l
hc l:irap rir,l: expar,dcr is usecl for removing installing
snap
l li
rll
JDT-3A
TrLt sr :r r-, r fq retainer plate holds snap rings expanded
dL|ifq.srr.'r)bly of parts on differential drive shaft.
.JDT-10
JDT-23
rhL. Ot.lA.r QTTNGE brake piston
installtng set compresses
the brake prston packing to prevent damage to packing when
piston assemblv rs lnstalled into the housing.
Consists ot:
A-JDT-23-1 Inner packing proteclor
B*JDT-23-2 Outer packing protector
Lrttro |,.JSA
JDT.24A
The spring washer compressor is used to compress the
spring{ype washers.
..\
t
JDT.26
The differential drive shaft installation tool set is used lo
speed up the assembly of gears, washers, snap rings, etc.
onto the differential driveshaft.
Consisls of:
A-JDT-26-2 Casting
B-JOT-26-1 Arbor
JDT-30
The bearing cup remover is used to remove the transmission
drive shaft rear bearing cup.
JDT-31
JDT-38
This bearing driver is used to install the bearing shaft in the
engine fan support housing.
JDT-42
The spring scale is used to measure differential drive shatt
rolling drag torque, and make other ,'pull,, lree
measurements.
Special Tools
JDT-46
JT01463
The puller is used to remove clutch shaJt piLot bushing.
ry@
JT01633
JT03296
The iitting assembly is used to connect the Service-Gard
Portable filter caddy to the transmission drain.
A-JT03296
B-JT03347
c-AT65849
D-AT65846
JT05470
l
Pressure Tesl Kit gauges, connectors, and hoses used
to
measure hydraulic pressures.
NOTE: This test kit does not contain filtings necessary for
all hydraulic tests. Additional fittings may be oriered
thru SERVICE-GARD or cross_referenced to other
kits. When using JTO3073 or JTO3074 screws use
an R264AB O-ring. When using JTO3072 spacer or
JTO3075 connector use R26375 O+ino.
JT05746
JT27702
JT27706
TY 3315
The beam type torque wrench is used for checking axle
bearing rolling drag torque.
FABRICATED TOOLS
NOTE: These tools can be made in a service shoD usino
common shop tools and tocally obtainsj m61pnp1l.
I
r...rnn -F,t r 1131
f;*;* HOUSING
(425.5 mm)
(25.4 mm)
1in.
I
f
(51 mm)
2 in.
L
_ (476.3 mm)
18.750 in.
I
4-ll2 lN.
(I I4 nm)
2- l/4 tN.
( 57 n]{n)
l-7lB lN.
( 48 mm)
D IA.
4 rN.
( 102 nm)
3/B lN.
(9 nYn )
DlA.--2
ir0Lts
3-ll2 lN.
ioy mm/ I
l4 tN.
( 356 r'xn)
25.4 mm 25.4 mm
(1 in.) (1 in.)
18.6 to 18.7 mm '18.6 to 18.7 mm
I
(0.732 to 0.736 in.) (0.732 to 0.736 in.)
16.8 to 16.9 mm '16.8 to 16.9 mm
(0.661 to 0.665 in.) (0.661 to 0.665 in.)
50.8 mm 100.08 mm
(2 in.) (3.94 in.)
22.9 to 23.1 mm 0.46 to 0.56 mm
(0.901 to 0.909 in.) (0.018 to 0.022 in.,
19.9 to 20.1 mm 19.9 to 20.1 mm
(0.783 to 0.791 in.) (0.783 to 0.791 in.)
39.9 mm 39.9 mm
( j.s7 in.) (1.s7 in.)
B 34.5 to 34.8 mm 34.5 to 34.8 mm
(1.36 to 1.37 in.) (1.36 to 1.37 in.)
c 29.7 to 30.0 mm 29.7 to 30.0 mm
( t.17 to 1.18 in.) (.1.17 to 1.18 in.)
D 50.8 mm 50.8 mm
(2 in.) (2 in.)
E 24.1 to 25.9 mm 0.46 to 0.51 mm
(0.9s to 1.02 in.) (0.018 to 0.02 in.)
F 22.O to 24.O mm 25.3 to 25.4 mm
(0.866 to 0.945 in.) (0.996 to 1.000 in.)
Litho in u.s.A.
99-41 TM-1354 (Sep-8s)
Extension, Rockshaft Valve Operating Arm
This tool is used during adjustment of operating arm of
rockshaft.
Niaterial:
(3 x 25 mm) 1/8 in. x 1-1 /2 in. cold rolled steel.
3/16 x 1.1/16 in. bolt with nut.
+++
O-l1 mm (7/16 In.)
P-19 mm (3/4 In.)
O-12 mm ( l/2 In.)
R-Spacgr
L-_- 5
7631N
a76:J27631 N 511;9900 BF 260485
J. Assemble the parts and lock two 5/8 in. nuts together
on the screw.
Material:
12.7 mm x 63.5 mm x i 53 mm H.R. Flat
(0.50 in. x 2.50 in. x 6 in.)
12.7 mm x 254 mm (0.S0 x 10 in.) Round B)-
Cc P
oq p
AF .-(9-^.
I
Hook, Planetary
The planetary hook is used for lifting components and is
tabricated from specified material. Bend rod as shown and
weld at O-ioint.
M.tsrlal Dlmonrlon
(44.5 mm)
1.750 in.
(19 mm)
0.750 in.
(470 mm)
(422 mm)
18.500 in.
16.625 in.
*\
IFIS
\K (102 mm)
4 in.
(559 mm)
22 in.
The axle jacking tool is made from specilied tubing with 2-9/16 x 14 in. Ready Rods. Use 4-9l16 in. nuts and
2-9l16 in, flat washers on the rods.
The axle jacking tool is used to remove the axle housing from the axle shaft.
% In. x 13 UNC
(38.10 mm)
1.500 ln.
(s8.10
39.70 rhm)
5.500 ln.
('t 14-30
mm)
I 4.500 ln.
I
I
ll --.] L-
' 1rz.zo
..1
l-
(50,80 mm)
--.1
I
0.500 ln
I
I
l
2.000 ln. (6.35 mm) (25.40 mrn)
i
0.250 In. '1.00O ln. I
-..1
(s0.80 mm)
2.000 ln-
The differential lifting tool is used to remove and install the differential housing
from the transmissron case.
The differential lifting tool is made as shown from specified matenat.
Litho in U.S.A.
TN4-13s4 (Sep-85)
Lift Tool, Planetary
This tool is used to remove and install planetary assembties
on M.F.W.D.
A-50.8 mm (2 In.)
B-t2.7mm (0.50 In.)
H0.0 mm (3.50 In.)
tH0.0 mm (3.50 In.)
E-165 mm (6.5 In.)
F-22 mm (.875 In.) % Orlll
Material:
12.7 mm x 50.8 mm x 90.0 H.R. Flat
(0.50 in. x 2 in. x 3.50 in.)
12.7 x 3O5 mm (.050 x 12 in.) Round
- arq
39 - I .535
.L752
44.5 -
a] .a - 2.264
t.l
67 .5 - ?.657
72., - 2.854
88 - 3.465
il
92 ' 3.622 tl
i 45 - 5.709
216 - 8.500 U
t 3 in, l
8 in.
(203 m')
3 in.
(76. trm)
F-r-r
I 8in.
ll (,03
I li
nnr
(lc2 dn)
I
Ll ul
(6 din)
l+
lTrt | (sr
2 in.
nn)
I L-.:-l |
5 ft. il-li--];,,.
| (sl| nn)
A-76.2 mm (3 In.)
B-3.1 mm (% in.)
C-l9.2 mm (Ya In.)
Oo
go
DRILL
N4odifiy D-0500 1ST Adapter Plate Set by drilling lower mounting bolt hote
in left and right hand engine mountrng brackets
out to 3/4
In. as indicated in drawing.
Material:
38 mm x 6.35 mm H.R. Flat
(1.50 in. x 0.25 in.) H.R. Flat
0.50 Hex nut
Stop, Pivot
This is used to prevent wheels and outer planetaries from
turning (2 required).
Material:
'12.7 mm x 90.0 mm H.B. Steel
(0.500 in. x 3.50 in.)
.f\-
L-Jg
l_l
tl t_
t-l I I
F l-
Gear remova tool rs used to pull the final drive gear from the axle housing.
,..--..--\.-
/n\A
/\1
\\r/v
A-19M7906 Cap Screw
B-JD5815 Grease Flttlng
C-l5 mm (5/8 In.)
(F9.5 mm (3/8 In.)
-r
\-L..J
.<
Y
In l
? LIF--@-r
[]
.
-@-
A-51 mm (2 in.)
8-25.4 mm (1 In,)
C-l3 mm (1/2 In.)
D-9.5 mm (3/8 In.)
E-5/32 In. drlll (Drllt deep enough so plns protrude
approxlmately 6 mm (1/d In.)
F-32 mm (l-1l4 In.)
G-Two (2) requlred
H-Headed plns rvlth heada cut ofl.
Pre8s In so 6 mm (1/4 In.) protrudes,
l-Weld (both sldes)