Ford New Holland 455D, 555D, 575D, 655D, 675D Series Tractor Loader Backhoe Service Manual 40045541

Brands: Ford / Ford New Holland / New Holland Agriculture

Equipment Type: Tractor Loader Backhoe

Manuals Type: Service Manual (Vol.1 - Vol.2)

Machine Model & Serial Number: 455D, 555D, 575D, 655D, 675D

Region: N/R

Book Code: 40045541

Issued: Reprinted Edition

Language: English

Pages: 1107

File Format: Portable Document Format (PDF)

Remark: The absolute 1107-page definitive factory repair bible for the Ford D Series tractor loader backhoes. Nuclear Level Value: Provides exhaustive overhaul procedures for 3-cylinder and 4-cylinder diesel engines (naturally aspirated and turbocharged). Features surgical disassembly and reassembly protocols for 4x4 and 8x8 power reversing transmissions, including torque converter lock-up circuits. Covers deep-level diagnostics for hydrostatic steering, planetary reduction rear axles, and the complete industrial loader/backhoe hydraulic system. Includes full chassis electrical schematics and cab air conditioning recovery/recycling procedures.

Table of contents

• SECTION 1 - ENGINE
  • 3-Cylinder Diesel Engine
    • Description and Operation
    • General Specifications
    • Lubrication System
    • Overhaul (Cylinder Head, Valves, Engine Front Cover, Oil Pan, Oil Pump, Connecting Rods, Pistons, Main Bearings, Flywheel, Crankshaft, Camshaft)
  • 4-Cylinder Diesel Engine
    • Description and Operation
    • General Specifications
    • Lubrication System
    • Overhaul (Cylinder Head, Valves, Engine Front Cover, Oil Pan, Oil Pump, Connecting Rods, Pistons, Main Bearings, Flywheel, Crankshaft, Camshaft)
  • Cooling System
    • 3-Cylinder Engine Description and Operation
    • 4-Cylinder Engine Description and Operation
    • Overhaul (Radiator, Thermostat, Water Pump)
  • Specifications and Special Tools
  • Troubleshooting
• SECTION 2 - FUEL SYSTEMS
  • Fuel System - General
    • Description and Operation
    • Adjustments (DPA and DPS Distributor Type Fuel Injection Pumps)
    • Bleeding the Fuel System
  • Fuel Tank, Filters and Fuel Lines Overhaul
  • Injectors - Ford 455D (Removal, Testing, Disassembly, Inspection, Reassembly, Installation)
  • Injectors - Ford 555D, 575D, 655D, 675D (Removal, Testing, Disassembly, Inspection, Reassembly, Installation)
  • Air Cleaners (Description and Operation, Overhaul)
  • Fuel Injection Pump - DPA Distributor Type
    • Description and Operation
    • Overhaul (Removal, Disassembly, Injection Pump Timing, Installation)
  • Fuel Injection Pump - DPS Distributor Type
    • Description and Operation
    • Overhaul
  • Turbocharger
    • Description and Operation
    • Overhaul (Removal, Disassembly, Cleaning, Inspection, Repair, Reassembly, Installation)
  • Troubleshooting, Specifications, and Special Tools
• SECTION 3 - ELECTRICAL SYSTEM
  • Wiring, Lights and Controls
    • Description and Operation (Harness Routing, Fuses and Relays, Instrument Console)
    • Troubleshooting and Repair (Wiring Harnesses, Bulb Replacement, Wiring Diagrams)
  • Battery
    • Description and Operation
    • Maintenance and Tests (Removal, Specific Gravity, Charging, Installation)
  • Starting System
    • Description and Operation
    • Overhaul (Starting System Test, Removal, Disassembly, Inspection, Reassembly)
  • Charging System - A127 55/70-Amp Alternator With Integral Regulator
    • Description and Operation (Rotor, Stator, Rectifier, Regulator and Brushes)
    • Service Precautions, Preliminary Checks, Initial Tests and Alternator Components Tests
    • Alternator Overhaul (Removal, Disassembly, Component Test, Inspection and Repair, Reassembly, Installation)
  • Troubleshooting, Specifications, and Special Tools
• SECTION 4 - TRANSMISSION
  • 4x4 Transmission
    • Description and Operation (Gear Ratios, Torque Converter, Oil Distributor, Hydraulic Pump, Solenoid Control Valve, Modulator Unit, Hydraulic Clutch Assemblies, Oil Flow, Power Flows, Synchronizer)
    • Overhauling the Transmission
    • Front End Overhaul (Separating Transmission from Engine, Torque Converter, Hydraulic Pump, Front Input Shaft and Clutch Housing)
    • Complete Overhaul (Gearshift Components, Output Shaft and Countershaft Gear Assemblies, Rear Cover, Pre-Load Checks)
    • Component Overhaul (Torque Converter, Hydraulic Pump, Oil Distributor, Solenoid Control Valve, Reverse Idler Gear, Output Shaft, Countershaft)
  • 8x8 Transmission
    • Description and Operation (Synchronized 8x8, Torque Converter, Lock-up Valve, Modulator Unit, Hydraulic Clutch Assemblies, Oil Flow, Power Flows, Synchronizer)
    • Overhauling the Transmission
    • Front End Overhaul
    • Complete Overhaul
    • Component Overhaul
  • Transmission Electrical Control Circuit
    • Basic Control Circuitry Description (Power-up, Neutral, Forward, Reverse, Torque Converter Lock-up)
  • Troubleshooting
    • Electrical (Dividing the system, Intermittent problems, Modulator control box)
    • Hydraulic (Control valve check, Flow test, Line pressure test, Oil-to-cooler tests, Stall test)
  • Specifications and Special Tools
• SECTION 5 - REAR AXLE AND BRAKES
  • Rear Axle and Wheel Brakes
    • Description and Operation
    • Rear Axle (Removal, Disassembly, Inspection and Repair, Reassembly, Installation)
  • Differential and Differential Lock Assembly (Disassembly, Inspection and Repair, Reassembly, Installation)
  • Drive Pinion Assembly (Removal, Disassembly, Inspection and Repair, Reassembly, Installation)
  • Brake Pedal Linkage and Cross-Shaft
  • Differential Lock Linkage
  • Twin Cable Hand Brake Operation
  • Planetary Gear Assembly (Disassembly, Inspection and Repair, Reassembly, Installation)
  • Rear Wheel Brakes (Removal, Disassembly, Inspection and Repair, Reassembly, Installation)
  • Specifications and Special Tools
• SECTION 6 - POWER TAKE-OFF
  • Independent PTO
    • Description and Operation
    • Pressure Regulating Valve and Control Valve - Pressure Tests
    • Pressure Regulating Valve (Removal, Disassembly, Inspection, Reassembly, Installation)
    • Control Valve Overhaul
    • Clutch Assembly Overhaul (Clutch Brake Seals, Clutch and Brake Assembly)
    • Reduction Gear Assembly (Disassembly, Inspection, Reassembly)
    • Hydraulic Pump (Description and Operation, Removal, Disassembly, Inspection, Reassembly, Installation)
    • Hydraulic Pump Drive Shaft Overhaul
  • Troubleshooting, Specifications, and Special Tools
• SECTION 7 - STEERING AND FRONT AXLE
  • Steering
    • Hydrostatic Steering Description and Operation (Column, Pump and Reservoir, Cooler, Motor, Hoses and Tubes)
    • Power-Steering Pump, Reservoir, and Cooler Overhaul
    • Hydrostatic Steering Motor Overhaul (Removal, Disassembly, Inspection, Reassembly, Installation)
    • Reservoir Filter and Hydraulic Tubes
    • Bleeding the Steering System
    • Troubleshooting and Pressure Testing
  • Two-Wheel Drive Front Axle
    • Description and Operation
    • Toe-In Adjustment
    • Front Wheel Hub and Spindle Overhaul
    • Steering Cylinder and Track Control Rod Overhaul
    • Front Axle Overhaul
  • Front-Wheel Drive Front Axle
    • Description and Operation
    • Planetary Reduction Assembly and Wheel Hubs Overhaul
    • Axle Shafts Overhaul
    • Steering Swivel Pin Bearings Overhaul
    • Steering Cylinder and Track Control Rod Overhaul
    • Front Axle Removal and Installation
    • Differential, Ring Gear and Pinion Assembly Overhaul
    • Drive Shaft Overhaul
  • Transfer Gear Assembly
    • Description and Operation
    • Overhaul (Removal, Disassembly, Inspection and Repair, Reassembly, Installation)
    • Transfer Gear Operating Cable Adjustments
  • Specifications and Special Tools
• SECTION 8 - HYDRAULIC SYSTEM, CONTROLS AND FRAME
  • Hydraulic Circuits (General Introduction)
  • Reservoir, Filter and Oil Cooler
    • Description and Operation
    • Reservoir Overhaul
    • Filter Overhaul
    • Oil Cooler Overhaul
  • Hydraulic Pump
    • Description and Operation
    • Overhaul (Removal, Disassembly, Inspection, Reassembly, Installation)
    • Hydraulic Pump Drive Shaft Overhaul
  • Backhoe Control Valve Assembly
    • Description and Operation (Circuit Relief Valves, Inlet End Cover, Outlet End Cover, Valve Spool Section)
    • Overhaul (Removal, Disassembly, Inspection and Repair, Reassembly, Installation)
  • Sideshift Hydraulic Clamping System
    • Description and Operation
    • Overhaul (Control Valve, Clamping Cylinders)
  • Loader Hydraulic Control Valve Assembly
    • Description and Operation
    • Overhaul (Removal, Disassembly, Inspection, Reassembly, Installation)
  • Swing System (Description and Operation)
  • Hydraulic Cylinders
    • Description and Operation
    • Overhaul (Removal, Disassembly, Inspection, Reassembly, Installation)
  • Flow Restrictor Valves (Description and Operation)
  • Backhoe Frame, Boom, Dipstick and Buckets, Control System, Hoses and Tubes
    • Description and Operation
    • Backhoe or Loader Counterweight Removal and Replacement
    • Backhoe Boom, Dipstick and Buckets Overhaul
    • Backhoe Swing Post, Carriage and Mainframe Overhaul
    • Backhoe Extendible Dipstick Overhaul
    • Backhoe Control System (Mechanical) Overhaul
    • Hoses and Tubes Overhaul
  • Loader Frame, Buckets, Control System, Hoses and Tubes
    • Description and Operation
    • Loader Bucket, Lift Arms and Subframes Overhaul
    • Loader Control System (Mechanical) Overhaul
    • Hoses and Tubes Overhaul
  • Hydraulic Troubleshooting and Pressure Testing
    • Hydraulic Pump Performance Testing
    • Circuit Relief Valves Test Procedure
    • Cylinder Packing Leakage Test
  • Specifications and Special Tools
• SECTION 9 - CAB
  • Cab Glass Installation
  • Air Conditioning
    • Description and Operation (Compressor, Condenser, Evaporator, Expansion Valve, Receiver/Drier)
    • Troubleshooting and Servicing (Discharging, Evacuating, Flushing, Charging, Leak Testing)
    • Air Conditioning Condenser, Receiver/Drier, Switches, Expansion Valve and Evaporator Overhaul
    • Air Conditioning Electrical Controls (Operation, Troubleshooting and Testing)
    • Compressor Overhaul (Clutch Disassembly, Shaft Seal Replacement, Cylinder Head Servicing)
  • Specifications and Special Tools
• SECTION 10 - SEPARATING THE TRACTOR
  • Front Cover or Oil Pan Removal
  • Engine Removal
  • Separating the Transmission from the Engine
  • Separating the Transmission from the Rear Axle
  • Backhoe Removal
  • Rear Axle Removal
• SECTION 11 - ACCESSORIES
  • Cold Start Kit
  • Backup Alarm
  • Heavy-Duty Seat Suspension Kit
  • Loader Auxiliary Valve Kits
  • Bolt-on and Weld-on Cutting Edges
  • 4:1 Loader Bucket
  • Multi-Purpose Bucket Forks
  • 3-Lever Backhoe Controls - Foot Swing Conversion
  • 4-Lever Backhoe Controls Conversion Kit
  • Hand Lever Controls Extendible Dipperstick Conversion Kit
  • Reversible Stabilizer Pads
  • Rear Window Defroster
  • Coolant Corrosion Inhibitor/Filter Kit
  • AM/FM Stereo Cassette Sound System
  • Front End Upper Side Weights
  • Backhoe Valve Power Beyond Kit
  • Rearview Mirror
  • Auxiliary Work Lamp - Front
  • Auxiliary Work Lamps - Rear
  • Rotating Beacon Kit
  • Driving Lamp and Hazard Flasher

Professional Surgical Insight
When overhauling the Ford D Series loader backhoes, strict adherence to hydraulic cleanliness and torque specifications is non-negotiable. For instance, when servicing the 8x8 transmission, the lock-up valve circuit engages without modulation; failure to diagnose the 3-second electronic delay properly often leads to unnecessary valve teardowns. During hydraulic cylinder rebuilds, the massive 1475 ft. lbs. torque required for the lift and crowd cylinder piston bolts demands specialized tools (torque multipliers) and Loctite 271 to prevent catastrophic rod separation under breakout force. Always observe the precise 0.063"-0.070" clearance when shimming the transmission forward and reverse clutch packs to prevent immediate clutch burn-out or sluggish modulation.