Part of the John Deere Repair Manuals.
When it is time to tear down the TSS transmission on your utility tractor, this 418-page John Deere 5403 repair manual pdf (OEM #tm8139) brings the factory teardown procedures for the 5403, 5600, 5603, 5605, 5700, and 5705 models. You get complete removal and assembly instructions for both the Carraro and LUK clutch systems. Inside, find step-by-step guidance for overhauling the mechanical front-wheel drive, rebuilding the Bosch hydraulic pump, bleeding the creeper transmission brakes, and servicing the planetary final drives. Verify your PTO clutch disc thickness measures between 7.6 and 6.6 mm, then lock down the clutch assembly attaching bolts to exactly 36 N.m. Quit wasting shop hours on guesswork. Download this bookmarked, searchable file right to your tablet, pull up the numbers you need, and get that tractor back in the dirt.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 6-38 | Safety (Recognize Safety Information, Understand Signal Words, Follow Safety Instructions, Handle Fluids Safely, Avoid Fires, Prevent Battery Explosions, Prepare for Emergencies, Prevent Acid Burns, Service Cooling System Safely, Handle Chemical Products Safely, Avoid High-Pressure Fluids, Park Machine Safely, Support Machine Adequately, Wear Protective Clothing, Work in Clean Area, Service Machines Safely, Work in Ventilated Area, Illuminate Work Area Safely, Replace Safety Signs, Use Proper Lifting Equipment, Keep ROPS Installed Properly, Service Tires Safely, Avoid Harmful Asbestos Dust, Avoid Heating Near Pressurized Fluid Lines, Remove Paint Before Welding or Heating, Use Proper Tools, Dispose of Waste Properly, Live with Safety) |
| Repairing the Electrical System | 39-68 | Group 05 - Battery, Starter Motor and Alternator, Group 10 - Electrical System Components, Group 15 - Wiring Harness |
| Clutch Housing, Tss Transmission | 69-80 | Safe Maintenance, Proper Tools, Engine/Clutch Housing Separation, Clutch Housing Retainer Replacement, Clutch Pedal Inspection and Adjustment |
| Clutch Assembly (Carraro & Luk) | 81-130 | Special Tools & Materials, Clutch Assembly Removal & Installation, Clutch Disassembly & Inspection, Clutch Assembly & Adjustment (Drive & PTO Fingers) |
| Tss Transmission | 131-203 | Other Material, Clutch Housing Separation/Installation, Gear Shift Lever Inspection/Repair, Transmission Removal/Disassembly/Assembly, Parking Brake Components |
| PTO Drive Shaft | 221-232 | Other Material, PTO Lever and Link Inspection/Repair, Standard Rear PTO Drive Shaft Assembly Removal/Installation, PTO Drive Shaft Assembly Disassembly/Assembly (540/540E) |
| Differential | 233-252 | Special Tools & Materials, Differential Assembly Removal/Installation, Differential Drive Shaft Inspection/Installation, Differential Lock Assembly, Adjusting Differential Cone End |
| Final Drives | 254-270 | Special Tools & Materials, Final Drive Turn Tool, Final Drive Assembly Removal/Installation, Planetary Drive Assembly Inspection/Installation, Shaft Assembly Removal/Installation |
| Front-Wheel Drive Engagement | 271-286 | Special Tools & Materials, PTO Lever and Linkage Inspection/Repair, MFWD Housing Removal/Installation, MFWD Housing Disassembly/Assembly, MFWD Drive Shaft Removal/Installation |
| Creeper Transmission | 287-291 | Creeper Transmission Removal/Installation, Lock Pedal Removal, Disassembly/Assembly of Creeper Transmission, Final Considerations, Bleeding Brakes |
| Repairing Steering and Brakes | 293-343 | Group 05 - Repairing Steering, Group 10 - Repairing Brakes, Group 15 - Steering Cylinder, 4x2 Shaft |
| Hydraulic Repair | 344-413 | Group 05 - Hydraulic Pump and Filter, Group 05A - Bosch Hydraulic Pump, Group 05B - Hydraulic Oil Cooler, Group 10 - Hydraulic Hitch, Group 15 - Selective Control Valve |
| Mechanical Front-Wheel Drive | 414-415 | Group 05 - Mechanical Front-Wheel Drive |
| ROPS | 416-418 | Group 10 - Roll-Over Protective Structure |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Carraro Clutch Assembly | (up to 13693 series) | p. 2 |
| LUK Clutch Assembly | (13694 series onwards) | p. 2 |
| Fuel shut-off solenoid replacement | Replace fuel shut-off solenoid (B) and O-ring | p. 44 |
| Bolts (C) Torque | 120 N.m (84 lb-ft) | p. 357 |
| Fitting (3) Torque | 28 N.m (21 lb-ft) | p. 352 |
| Approximate transmission capacity | 41.8 L (11.04 U.S. gal) | p. 352 |
| Main relief valve torque | 51 N.m (38 lb-ft) | p. 34 |
| Overpressure relief valve torque | 34 N.m (25 lb-ft) | p. 35 |
| Metric Bolt Torque (M12, Class 12.9, Lubricated) | 130 Nm (95 lb-ft) | p. 141 |
| SAE Bolt Torque (1/2 inch, Grade 8, Lubricated) | 120 Nm (88 lb-ft) | p. 329 |
| Clutch Pedal Play | 25-35 mm (0.984-1.377 In) | p. 80 |
| Clutch Assembly Attaching Bolts Torque | 36 N.m (27 lb-ft) | p. 103 |
