This is the factory book, publication SE 4840-8, all 1492 pages of it - not a thinned-down aftermarket reprint. It covers the Ford New Holland Series 40 tractors 5640, 6640, 7740, 7840, 8240 and 8340 built 1991 to 1995, plus the Series S models S90 and S100, which are the Series S versions of the 6640 and 7740. You get full engine overhaul on both the 4-cylinder (268 and 304 cu in) and 6-cylinder (401 and 456 cu in) diesels, the 8x2, 12x12 and 16x16 transmissions with Dual Power, CCLS hydraulics and Electrolink draft control, IPTO, axles, brakes, hydrostatic steering, cab air conditioning, wiring schematics, and the fault finding and calibration procedures added for post November 1995 models.
What's Inside This Ford 5640-8340, S90, S100 Manual
| System | Pages | Key Topics |
|---|---|---|
| Engine Systems | 19-78 | Engine Overhaul, Cooling System, Cylinder Head Assembly, Crankshaft and Camshaft Assembly, Lubrication System |
| Fuel Systems | 79-188 | Fuel System General, Air Cleaner (Dry and Wet), Injectors, Fuel Pump, Turbocharger |
| Electrical Systems | 189-386 | Wiring Diagrams, Electrical Instrument Cluster, AIC and AEIC Instrument Clusters, Alternators, Starter Motors, Batteries, EIC Fault Finding (Post November 1995 Models) |
| Clutches | 387-398 | Clutch Overhaul |
| Transmission Systems | 399-822 | 16x16 Transmission, 12x12 Transmission, 8x2 Transmission, Dual Power Assembly, 8x2 Reduction Gearbox, 16x16 Quad Mod Transmission, Fault Finding and Calibrations (Post November 1995 Models) |
| Power Take Off Systems | 823-860 | Independent PTO (IPTO) Systems |
| Rear Axle and Brakes | 861-901 | Rear Axles, Brakes |
| Hydraulic Systems | 902-1249 | Closed Centre Load Sensing (CCLS) Pump, Electrolink Electronic Draft Control, Hydraulic Lift Assembly with Top Link Sensing, Fixed Displacement Gear Type Pumps, Remote Control Valves, Hydraulic Trailer Brakes, Assist Rams, Electrolink Fault Finding and Calibration |
| Steering Systems | 1250-1280 | Hydrostatic Steering Systems |
| Front Axle | 1281-1364 | Two Wheel Drive Axle, Four Wheel Drive Axle, Transfer Box, New Holland Class 2 and 3 Four Wheel Drive Axles |
| Cab | 1365-1430 | Air Conditioning, Sanden SD7H15 Compressor Overhaul |
| Separating the Tractor | 1431-1467 | Safety Cab and Platform Removal, Vehicle Separation |
| Electrical Connector Identification and Schematics | 1468-1492 | Connector Identification, Electrical Schematics |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Engine cylinders | 4 (5640, 6640, 7740) / 6 (7840, 8240, 8340) | p. 19 |
| Engine stroke | 4.4 in (111.8 mm) on 5640 and 7840 / 5.0 in (127.0 mm) on 6640, 7740, 8240, 8340 | p. 19 |
| Engine displacement | 268 cu in (5640), 304 cu in (6640, 7740), 401 cu in (7840), 456 cu in (8240, 8340) | p. 19 |
| Cylinder head bolt torque | 115 / 140 / 160 lbf ft (156 / 190 / 217 Nm) in three stages | p. 33 |
| Rear PTO speed | 540 rev/min at 1900 engine rev/min | p. 825 |
| PTO speeds available | 540 and 1000 rev/min | p. 857 |
| Lift cylinder relief valve | 2850-3050 lbf/in2 (197-210 bar) | p. 1033 |
| Hydrostatic steering relief pressure | 2500 lbf/in2 (172 bar) | |
| Rear axle and transmission oil refill capacity | 60.6 litres (13.3 Imp galls, 16.0 US galls) | |
| Hydraulic oil specification | Ford Specification ESN M2C134 D | |
| Hydraulic oil cooler bypass valve | opens at 100 lbf/in2 (7 bar), nominal 68 C | |
| Pump driveshaft gear retaining nut torque | 86-90 lbf ft (117-123 Nm) | |
| Production date code year key | 1 = 1991, 2 = 1992, 3 = 1993, 4 = 1994, 5 = 1995 | p. 7 |
| All models | ||
| Engine bore | 4.4 in (111.8 mm) | p. 19 |
| 5640, 6640 with fixed displacement pump, without assist rams | ||
| Maximum lift capacity at link ends | 6350 lb (2880 kg) | p. 1071 |
| Closed centre load sensing pump: lift, remote valves, auxiliary | ||
| Maximum system pressure | 2800 lbf/in2 (193 bar) | |
| tractors with fixed displacement tandem gear pump | ||
| Fixed displacement pump maximum pressure | 2650 lbf/in2 (183 bar) | |
| Closed centre load sensing pump | ||
| Standby pressure | 310-350 lbf/in2 (21-24 bar) | |
| CCLS pump | ||
| Low pressure circuit regulation | 250-280 lbf/in2 (17-19 bar) | |
| CCLS variable displacement piston pump | ||
| Charge pressure | 23-50 lbf/in2 (1.6-3.4 bar) | |
Ford 5640-8340, S90, S100 Common Problems This Manual Covers
Hydraulic lift is sluggish or will not raise an implement
Before condemning the pump, test pressures against the printed specs: CCLS standby should be 310-350 lbf/in2 and maximum system pressure 2800 lbf/in2. The Hydraulic Systems section covers CCLS pump overhaul, the lift assembly with top link sensing, and Electrolink fault finding to separate a lazy pump from a filter or valve problem.
Manual Section: Hydraulic Systems - CCLS pump, hydraulic lift assembly, Electrolink fault finding p. 1033Engine overheats under load
Usually a stuck thermostat, tired water pump or a radiator packed with chaff. The cooling system part of the Engine Systems section gives test procedures, water pump overhaul and thermostat specs so you replace the actual failed part instead of parts-cannon guessing on a hot harvest day.
Manual Section: Engine Systems - Cooling system p. 67Transmission slips or will not engage a range
Start with fluid: refill capacity is 60.6 litres of Ford spec ESN M2C134 D, and low or wrong oil mimics worn clutch packs. The Transmission Systems section then covers Dual Power assembly overhaul and, for post November 1995 tractors, fault finding and calibration for the 16x16 before you split the tractor.
Manual Section: Transmission Systems - Dual Power assembly, fault finding and calibrations p. 770Front wheel hub noise, wobble or grease leaking past the seal
Worn or badly repacked bearings and a torn hub seal will eat a spindle if left. The Front Axle section covers both the two wheel drive axle and the four wheel drive axles including the New Holland Class 2 and 3 units, with bearing preload and seal replacement procedures.
Manual Section: Front Axle - two wheel drive and four wheel drive axles p. 1281Frequently Asked Questions
What are the cylinder head bolt torque specs?
Three stages: 115 lbf ft (156 Nm), then 140 lbf ft (190 Nm), then 160 lbf ft (217 Nm). The manual gives the full tightening sequence diagram in the cylinder head assembly section (page 33 for the torque table), so you are not guessing bolt order on a fresh head gasket. p. 33
What do the instrument cluster error codes mean?
These tractors have no OBD port and no scan tool codes - the only codes are the Electronic Instrument Cluster's own Error Codes 1 through 6. For example, Error Code 1 is an engine oil pressure sender short or open circuit, Error Code 3 is a fuel level sender short, Error Code 4 the same sender open circuit. The manual's EIC fault finding section (post November 1995 models) walks each one back to the sender or wiring. Ignore forum talk of E01/E02 codes - those do not exist on this machine.
How do I calibrate the 16x16 transmission or Electrolink after a repair?
The fault finding and calibration procedures for the 16x16 transmission and the Electrolink electronic draft control on post November 1995 tractors are in the book, step by step. If you have swapped a clutch pack, control valve or draft sensing components and the tractor now shifts or lifts oddly, this is the section that puts it right.
What PTO speeds does it run, and at what engine speed?
540 and 1000 rev/min PTO speeds are available, with 540 rev/min reached at 1900 engine rev/min. The Independent PTO (IPTO) section covers overhaul of the clutch pack and controls if engagement gets lazy under load. p. 857
How much will the rear linkage lift?
As a grounded example from the spec tables: 6350 lb (2880 kg) at the link ends on a 5640 or 6640 with the fixed displacement pump and no assist rams. Fit assist rams or the CCLS pump and the figures change - the manual tables every configuration, plus the lift cylinder relief valve setting of 2850-3050 lbf/in2 for testing. p. 1071
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