This is Ford service manual 40231090 (SE3660), reprinted 8/94, for the 2600, 3600, 4100, 4600, 5600, 6600, 6700, 7600 and 7700.
It comes in three volumes and thirteen parts. It covers diesel and gasoline engines, fuel injection, and electrical systems with wiring diagrams. It also covers clutches, transmissions, PTO, rear axle and brakes, hydraulics, steering, front wheel drive, cabs and remote control valves.
The engine, fuel system and electrical parts each close with a trouble shooting and specifications chapter, and the hydraulic part includes hydraulic system schematics.
What's Inside This Ford 2600–7700 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Foreword, Serial Number and Date Codes | 1-10 | Foreword, Serial Number, Date Code |
| Diesel Engines | 11-52 | Cylinder Head, Valves, Pistons, Connecting Rods, Crankshaft, Timing Gears, Lubrication |
| Cooling System | 53-60 | Thermostat, Water Pump, Radiator, Fan |
| Gasoline Engines | 61-64 | Gasoline Engine, Governor |
| Engine Trouble Shooting, Specifications and Special Tools | 65-86 | Trouble Shooting, Specifications, Torque, Special Tools |
| Fuel Systems, Gasoline and Diesel | 87-116 | Carburetor, Fuel Pump, Bleeding, Fuel Filter |
| Air Cleaners and Injectors | 117-128 | Air Cleaner, Injector |
| Fuel Injection Pumps, Distributor and In-Line Type | 129-178 | Distributor Type, In-Line Type, Pump Timing, Delivery Valve |
| Turbocharger | 179-188 | Turbine, Compressor Wheel, Bearing, Boost Control Unit |
| Fuel System Trouble Shooting, Specifications and Test Plans | 189-218 | Trouble Shooting, Specifications, Test Plan, Nozzle |
| Wiring, Lights, Switches and Instrumentation | 219-260 | Wiring, Lights, Switches, Instrumentation, Instrument Cluster, Sender, Turn Signal, Key-Start Switch, Fuse |
| Battery and Starting System | 261-290 | Battery, Specific Gravity, Starting System, Starter Motor |
| Charging Systems, Alternators with Integral and External Regulator | 291-342 | Alternator, Integral Regulator, External Regulator |
| Ignition System | 343-370 | Distributor, Ignition Coil, Spark Plug |
| Electrical Trouble Shooting, Specifications and Wiring Diagrams | 371-420 | Trouble Shooting, Specifications, Wiring Diagram |
| Clutches | 421-472 | Single Clutch, Double Clutch, Release Bearing |
| Transmission Systems and Dual Power | 473-570 | Eight Speed Transmission, Seven and Eight Speed, Dual Power, Trouble Shooting |
| Power Take-Off | 571-618 | Transmission P.T.O., Live P.T.O., Independent P.T.O., Trouble Shooting |
| Rear Axle and Brakes | 619-700 | Rear Axle, Brakes, Differential Lock |
| Hydraulic Systems | 701-866 | Hydraulic System Circuits, Hydraulic Power Lift, Lift Cylinder, Load Monitor, Hydraulic Pumps, Adjustments |
| Steering Systems | 867-948 | Steering Gear, Power Assisted Steering, Hydrostatic Steering |
| Front Axle and Front Wheel Drive | 949-1108 | Front Axle, Front Wheel Drive, Transfer Box |
| Safety Cabs, Platforms and Separating the Tractor | 1109-1178 | Safety Cab, Platform, Separating the Tractor, Door, Window, Roof, Removal and Replacement, Splitting |
| Air Conditioning, Cab Heating, Remote Control Valves and Trailer Brake Valve | 1179-1274 | Air Conditioning, Cab Heating, Remote Control Valves, Trailer Brake Valve, Compressor, Condenser, Evaporator, Expansion Valve, Refrigerant |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Diesel compression ratio | 2600 17.3:1; 3600, 4100, 4600, 5600, 6600 and 6700 16.3:1; 7600 and 7700 15.6:1 | p. 70 |
| Firing order | 1-2-3 (3-cylinder); 1-3-4-2 (4-cylinder) | p. 70 |
| Exhaust valve lash clearance (cold) | 0.017-0.021 in (0.43-0.53 mm) | p. 71 |
| Intake valve lash clearance | 0.014-0.018 in (0.36-0.46 mm) | p. 72 |
| Oil pump relief valve pressure | 60-70 lbf/in² (4.1-4.8 bar) at 2000 rev/min | p. 78 |
| Engine oil with filter, 2600, 3600, 4100, 4600 (Imp pts / U.S. pts / litres) | 11.7 / 14 / 6.6 | p. 79 |
| Engine oil with filter, 5600, 6600, 6700, 7600, 7700 (Imp pts / U.S. pts / litres) | 15 / 18 / 8.5 | p. 79 |
| Cooling system with heater, 2600, 3600, 4100, 4600 (Imp pts / U.S. pts / litres) | 20 / 24 / 11.4 | p. 80 |
| Cooling system less heater, 2600, 3600, 4100, 4600 (Imp pts / U.S. pts / litres) | 18.3 / 22 / 10.4 | p. 80 |
| Thermostat opening temperature | 188°F (87°C) | p. 80 |
| Cylinder head bolts (engine cold) | 105-115 lbf ft (143-156 Nm) | p. 81 |
| Connecting rod nuts | 60-65 lbf ft (82-88 Nm) | p. 81 |
| Flywheel-to-crankshaft bolts | 100-110 lbf ft (136-149 Nm) | p. 81 |
| Crankshaft pulley-to-crankshaft | 150-180 lbf ft (203-244 Nm) | p. 81 |
| Dual Power, normal drive engaged pressure | 150-180 lbf/in² (10.3-12.4 bar) | p. 560 |
| Dual Power, power drive engaged pressure | 155-185 lbf/in² (10.7-12.8 bar) | p. 560 |
| Independent P.T.O. (single speed) | 540 rev/min at 1900 engine rev/min | p. 614 |
| Independent P.T.O. (two-speed) | 540 rev/min at 1900 and 1000 rev/min at 2060 engine rev/min | p. 614 |
| Hydraulic pressure relief valve, fully opening | 2550-2650 lbf/in² (178-186 bar) | p. 852 |
| Battery | 80 AH or 128 AH, 12 V | p. 381 |
Ford 2600–7700 Series Common Problems This Manual Covers
Diesel engine does not develop full power.
Clean the air cleaner or renew the element if it is clogged, then check and reset the valve lash. If power is still down, pull the injectors and clean and reset them. If compression is low, the engine needs new piston rings or a re-bore or re-sleeve. The Engine Trouble Shooting chart lists each cause with its remedy.
Manual Section: Engine Trouble Shooting, Specifications and Special Tools p. 66Engine stalls or lugs when shifting from normal drive to power drive (Dual Power).
This points to the direct drive clutch inside the Dual Power unit. Look for a scored, burred or binding direct drive clutch piston and replace it if you find one. Check the piston return spring and renew it if it is broken or defective. Replace warped or defective direct drive clutch plates. Before you button it up, check the engaged pressures against the specs in the Transmission Systems and Dual Power part.
Manual Section: Transmission Systems and Dual Power p. 559PTO engages but will not disengage.
Start outside the housing with the selector lever linkage. If it is broken, repair it. If the linkage is sound, check the I.P.T.O. control valve, because a stuck piston holds the clutch on. Replace parts as needed. A broken I.P.T.O. clutch return spring causes the same problem and has to be replaced. The Power Take-Off part covers each check.
Manual Section: Power Take-Off p. 614Noisy power steering pump.
Check the oil level in the reservoir first, and fill it with the correct grade and quantity of oil. If the noise stays, there is air in the system. Check all the tubing for loose connections and tighten them. Then purge the system.
Manual Section: Steering Systems p. 941Frequently Asked Questions
Which Ford tractors does this service manual cover, and what is in it?
It covers the Ford 2600, 3600, 4100, 4600, 5600, 6600, 6700, 7600 and 7700. This is Ford manual 40231090 (SE3660), reprinted 8/94, in three volumes and thirteen parts. The 2600, 3600, 4100 and 4600 run 3-cylinder diesels. The 5600 to 7700 get 4-cylinder diesels with a dynamic balancer, and the 7600 and 7700 are turbocharged. The 3-cylinder gasoline engines on the 2600, 3600 and 4600 are covered too. The parts start with engine, fuel and electrical, then clutches, transmissions, PTO, rear axle and brakes. After that come hydraulics, steering, front axle and front wheel drive, cabs, separating the tractor and accessories. p. 1
What are the Ford 2600–7700 engine oil and cooling system capacities?
Engine oil with filter is 11.7 Imp pts / 14 U.S. pts / 6.6 litres on the 2600, 3600, 4100 and 4600. The 5600, 6600, 6700, 7600 and 7700 take 15 / 18 / 8.5. The cooling system on the 2600 to 4600 holds 20 / 24 / 11.4 with a heater and 18.3 / 22 / 10.4 without one. The thermostat opens at 188°F (87°C). p. 79
What are the Ford 2600–7700 valve lash settings and main engine torques?
Exhaust lash is 0.017-0.021 in (0.43-0.53 mm) cold, and intake lash is 0.014-0.018 in (0.36-0.46 mm). Cylinder head bolts go to 105-115 lbf ft (143-156 Nm) with the engine cold. Connecting rod nuts are 60-65 lbf ft (82-88 Nm) and flywheel-to-crankshaft bolts are 100-110 lbf ft (136-149 Nm). The crankshaft pulley takes 150-180 lbf ft (203-244 Nm). Oil pump relief valve pressure is 60-70 lbf/in² (4.1-4.8 bar) at 2000 rev/min. The firing order is 1-2-3 on the 3-cylinder engines and 1-3-4-2 on the 4-cylinders. p. 71
What are the PTO speeds and Dual Power pressures?
The single-speed independent PTO gives 540 rev/min at 1900 engine rev/min. The two-speed version gives 540 rev/min at 1900 and 1000 rev/min at 2060 engine rev/min. Dual Power should read 150-180 lbf/in² (10.3-12.4 bar) with normal drive engaged and 155-185 lbf/in² (10.7-12.8 bar) in power drive. The hydraulic pressure relief valve opens fully at 2550-2650 lbf/in² (178-186 bar). p. 614
Does the manual include wiring diagrams and hydraulic schematics?
The electrical trouble shooting chapter has wiring diagrams for tractors with and without cabs. They are split by the letter 'A', 'B' or 'C' stamped before the serial number, which identifies the assembly plant. The 6700 and 7700 have their own diagrams, and so do the gasoline tractors. The hydraulic systems part has schematics in Figure 1 for the 2600 to 4600 and Figure 13 for the 5600 to 7700. It also has oil flow diagrams for neutral, lowering, raising and auxiliary service. p. 387
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