fitting guide for s.44103 full engine · 2016. 1. 15. · 3 these parts are sparex parts and are...

1 These parts are Sparex parts and are not manufactured by the Original Equipment Manufacturer. Original Manufacturer’s name, part numbers and descriptions

are quoted for reference purposes only and are not intended to indicate or suggest that our replacement parts are made by the OEM.

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UK

This guide contains the following pieces of information

• 59 easy to follow steps

• Service interval details

• Handy hints & tips

“Repower” your tired tractor

Fitting guide forS.44103 full engine



Sparex Quality & Tech Centre www.sparex.com

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Full Engine www.sparex.com

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Renew your old Massey Ferguson 135 or 240 tractor with a new Sparex replacement full engine – S.44103

Sparex the global tractor parts and accessories specialists have recently introduced a replacement full engine

suitable for the MF135 & MF240 models giving these tractors an extended life for many years to come.

This new lip seal type engine rated at 50hp is ideally suited to tractors built within the last 40 years fi tted

with a Perkins AD3.152 lip seal engine.

If we go back another 10 years to December 1964 the MF135 was fi rst introduced using this famous Perkins

direct injection three cylinder engine, developing 45hp.

Sparex’s Quality and Technical Centre at their Exeter Headquarters now have a fully equipped workshop so

when a local 1968 MF135 needed a new engine this was an opportunity not to be missed.

One or two minor problems were expected with this “repower” especially when replacing this

engine into this early tractor, so in the next few pages we see how a full engine swap was carried out.

This new engine comes complete with water pump, back plate and all fuel injection components;

it doesn’t however include the fl ywheel, dynamo/alternator or starter motor.

Down time should be kept to a minimum with this step by step guide. Each engine is supplied with a fi tting

kit containing all the additional parts needed to complete the repower with the minimum fuss.

The tractor in question is a late swept axle example still carrying its original aluminium head lamp cowls.

It was originally sold to a farmer near Honiton, when he retired in 1978 it was bought by a dairy farmer

near Cullompton and for the next 45 years gave sterling service until that farmer retired.

It was then sold to Sparex employee and classic tractor enthusiast George French.

Tractor Details:

MF135

Date of 1st Registration – 3rd September 1968

Recorded Hours – 5560

Serial Number – 106688




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1. 1968 MF135 in need of a replacement engine, which is now available from Sparex under part number S.44103. An increase in horsepower from 45 to 50 will give this tractor a new lease of life.

2. With the battery, bonnet bolts and loader brackets removed and the headlamp wires disconnected. Removal of the bonnet took place.

3. With the cooling system drained, the top and bottom hoses where loosened and the radiator removed after undoing the top securing bolt and bottom retaining nuts.

4. Next was to remove the fuel tank this was done by removing the fuel tap pipe, reservoir pipes, sender unit wiring and four fi xings.




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5. Removal of the fan blade is carried out by bending back the tabs and removing the four bolts. This is also a good time to inspect the blade for metal fatigue.

6. With the battery leads and other wiring disconnected the starter motor is removed; the inner bolt is best removed with a socket and extension bar placed behind the starter motor.

7. As this is an early swept axle tractor the drag links and radius rods have to be removed after securely placing a jack under the clutch housing.

8. Six 5/8” UNC bolts hold the front axle casting to the front of the engine, with these removed the axle can be wheeled away revealing the engine fully.




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9. After removing the air cleaner hose, fuel pipes, oil pressure gauge pipe and the various linkages the engine leveller is attached to the lifting brackets ready for removal.

10. All clutch housing bolts can be removed after the engine has been supported with a suitable crane. Not forgetting the central bolt at the top of the clutch housing.

11. Pressing down on the clutch pedal by hand moves the engine away from the gearbox. After a quick check that everything has been disconnected, the engine can now be moved away fully.

12. With the original engine removed and placed next to the new Sparex engine the differences can be noted and work can start swapping the parts over.




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13. Fit both the inlet and exhaust manifolds from the original engine. New gaskets are supplied. The rear lifting bracket was also swapped to allow the air cleaner pipe to fi t correctly.

14. Fit the two locating dowels, six bolts and two socket screws which hold the back plate to the engine. (Sparex engines are supplied with this back plate bolted in position).

15. To make fi tting the fl ywheel much easier a long ½” UNF bolt can be used as a locating dowel. If this is unavailable a short ½” UNF bolt can be used with its head removed and a slot cut in the end for a screwdriver.

16. Position the fl ywheel with the seventh hole in line with the extra hole in the fl ywheel boss, this ensures the timing marks on the fl ywheel are in the correct position. Remember to remove the locating bolt from the previous step.




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17. With the lock taps and bolts in position a ½” drive socket prevents the fl ywheel from turning when the securing bolts are torqued to the correct setting.

18. With fl ywheel bolts tightened to the correct torque*, lock tabs bent over. The spigot bearing is fi tted gently using a wooden drift to prevent damage. Remember to remove the ½” drive socket!!

*75ft/lbs or 105nm

19. It is always good practice to check the clutch plates on the gearbox input shafts before fi tting the clutch components to the fl ywheel

20. A centraliser tool* is used when fi tting the clutch cover and transmission plate to the fl ywheel. (The 12/10” clutch and fl ywheel is replacing the original 11/9” assembly).

*S.41531




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2423222121. Six 5/16” UNC bolts and spring washers hold

the clutch cover to the fl ywheel. Remember to remove the three ¼” UNC transport bolts and discard.

22. Check the centraliser tool slides in and out easily with the clutch plates and also the spigot bearing. Minor adjustment can be made by gently tapping from side to side.

23. Adjustment of the three clutch levers are preset on a new clutch cover and only need adjusting on rebuilt units using a special bridge tool.

11” Clutch – Bridge Tool S.41534

12” Clutch – Bridge Tool S.41533

24. The PTO clutch adjusting screws should have a gap of 0.080”. This can be checked with a feeler gauge. Again, this should only need adjusting on rebuilt units.

11” Clutch – Feeler Gauge S.41536

12” Clutch – Feeler Gauge S.41535




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2827262525. A new thrust bearing should always be fi tted,

with the gearbox shafts inspected a small amount of high temperature grease should be applied to the input shaft splines.

26. With the fl ywheel and clutch now fi tted, the engine is ready to refi t to the gearbox using the engine leveller and crane.

27. The engine can now be positioned square to the gearbox and moved rearwards until resistance is felt. Caution must be taken here not to cause any internal damage to the gearbox or clutch.

28. By engaging the tractors PTO lever, the shaft can be turned with a small bar which helps to align the clutch PTO plate splines correctly.




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3231302929. With the PTO clutch now engaged, select a low

gear and rotate the fl ywheel with a screwdriver until the transmission clutch engages.

30. Homemade clamps using 7/16” UNC threaded rod, help to hold everything square and also helps to pull the two halves together. The springs used here are from the old MF clutch.

31. All gearbox bolts can now be fully tightened. Using the set of reducing bushes supplied if required for these bolts. Do not forget the central bolt at the top.

32. Now is the time to check the clutch operation, both the transmission and the PTO. If a fault exists, it is much easier to check and adjust accordingly at this stage.




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3635343333. Refi t the starter motor with its three securing

bolts using a socket and extension bar for the inner bolt. Connect the wiring and battery leads.

34. Be very careful when refi tting the fuel pipes as these are very easy to cross thread. The tachometer cable and air cleaner hose can also be connected.

35. Connect the throttle linkage, stop rod and the fuel pipes on the left hand side of the engine. Check throttle linkage and adjust on the turnbuckle if necessary.

36. A new adaptor had to be made to fi t the oil pressure pipe as the new engines are tapped to a different size. An adaptor and oil pipe are supplied with the new engines.




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4039383737. A spacer, fl at washer and selection of shims are

supplied to fi t the front axle correctly to the new sump. Fit the correct thickness of shims after measuring the gap with feeler gauges.

38. Two M16 coarse bolts 250mm long are supplied to replace the 5/8” UNC bolts removed from the old axle casting to engine sump, as the new sump has metric threads.

39. After tightening all six front axle casting bolts, refi t the drag links and track rods to both sides of the tractor. The foot throttle assembly can also be refi tted.

40. Refi t the fan blade using either the original lock tabs (if they are in serviceable condition) or the new bolts with Nutlock B243 or a similar thread lock solution.




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4443424141. For early tractors such as this MF135 the

thermostat housing has to be changed to accommodate the earlier capillary tube type water temperature gauge.

42. With the new thermostat housing fi tted the temperature sensor securing nut fully tightens against the internal counter bored hole. Now is a good time to check all the hose clips.

43. The old top hose to thermostat casting is reused as this holds the two bolt and spring assemblies used to secure the front of the fuel tank.

44. Two 3/8” UNC holes have to be tapped into the side of the timing case to hold the dynamo bracket in position. For applications fi tted with an alternator, this modifi cation isn’t required.




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45. With the dynamo and its fi xing bracket secure, a new fan belt is fi tted along with a new dynamo pulley guard; a safety requirement for this tractor.

46. Servicing of the air cleaner is a must for a new engine, so thoroughly clean out any dirt and debris from the bowl. Fill to the correct level with new engine oil.

47. Refi t the radiator to the front axle casting with rubber mounting pads. Fit the top stay bar and tighten the top and bottom hose clips. Ensure the fan blade rotates freely.

48. Check that the engine drain plug is tight before fi lling the engine with good quality engine oil to the correct level. Also fi ll the cooling system with a good antifreeze mix.




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5251504949. Check the clutch pedal free travel and adjust so

that a 3/8” gap exists between the pedal and the underside of the foot rest. Check also the PTO operation.

50. Replace the two fuel fi lters. If these are dirty remove the tap from underneath the fuel tank and clean or replace the white pencil fi lter also.

51. With a small test tank supplying fuel to the lift pump, place the return pipe into the top of the tank so the fuel system can be bled.

52. With the bleed screws open diesel fuel can now be pumped into the fi lters by operating the hand primer pump on the lift pump until all the air is removed.




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5655545353. The same operation is carried out with the bleed

screws on the injector pump. Firstly bleed the bottom fi tting followed by the top one. Ensure that the stop rod is fully in.

54. Undo one injector pipe either at the pump end or the injector end, connect the battery and crank over with the starter key. When the engine starts tighten the injector pipe fully. Keep an eye on the oil pressure at this time.

55. A quick inspection inside the rocker cover ensures the oil is getting to the top of the engine. This step isn’t always necessary, but it is good practice to check that everything is working as it should.

56. Whilst the rocker cover was removed we checked the tappet clearance. With number one valve down we checked tappets 4 & 6. With number 6 valve down, we checked all other tappets. This step isn’t necessary with the installation, as all the tappet clearances are checked at the factory prior to delivery. This step is necessary for the fi rst service at 25/50 hours. When re-torqueing the Cylinder Head.




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59585757. Stoneleigh grey paint is now applied after

all traces of oil and diesel has been removed. Check oil and water levels and top up if necessary.

58. Fuel tank and bonnet now back on and the fuel system re-bled. Check the clutch pedal adjustment and operation. The loader brackets and grille guard where also refi tted at this time

59. With many of these tractors being around the 50 year old mark, a Sparex “Repower”, new replacement engine is an option to give your beloved tractor a second lease of life.

For Ancillary Products such as – Starter Motors, Alternators, Dynamos, Fan Blades, Fan Belts, Flywheels, Clutch Assemblies....

Go to www.sparex.com




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Service IntervalsA – First Service at 25/50 hours

B – Every day or every 8 hours

C – Every 250 hours or 4months

D – Every 500 hours or 12months

E – Every 2500 hours

A B C D E Description

X X Check Coolant Level

X Check Drive belt

X X Check for water in the fuel pre-fi lter (1)

X Renew the fuel fi lter element(s)

X Ensure that the atomisers are checked (2)

X Ensure the idle speed is checked and adjusted, if necessary (2)

X Check the amount of lubricating oil in the sump

X X Check the lubricating oil pressure at the gauge (1)

X X Renew the lubricating oil

X X Renew the canister(s) of the lubricating oil fi lter

Clean the air cleaner or empty the dust bowl of the air fi lter

X - Extremely dusty conditions

X - Normal conditions

X Clean or renew the air fi lter element, if it has not be indicated earlier

X Re-torque all Cylinder Head Studs & Bolts (2)

X X Ensure that the tappet clearances are checked and adjusted, if necessary (2)

X Ensure that the alternator, starter motor etc. are checked

CapacitiesEngine Oil – 12pints (6.8litres)

Cooling – 8.5 pints (4.8litres) engine only

Torque SettingsFlywheel bolts – 75Lbs/ft (105Nm)

Tappet adjusting Nuts 20lbs/ft (27Nm)

Cylinder Head Studs and Bolts 70lbs/ft (95Nm)

Tappet AdjustmentCold – 0.010” (0.25mm)

Hot – 0.012” (0.31mm)

Adjustment SequenceNumber 1 valve open – adjust number 4 & 6

Number 6 valve open – adjust number 1, 2, 3 & 5

Clutch Tools

• Centralizer – S.41531

• Bridge Tool – 11” Clutch S.41534, 12” Clutch S.41533

• PTO Gauge – 11” Clutch S.41536, 12” Clutch S.41535

Tools

• A good range of workshop tools

including a ½” drive socket set. S.21649

• A good quality engine crane.

• An engine leveller (S.27489).

• Hand Cleaner (S.8007)

(1) If there is one fi tted

(2) By a person who has had the correct training

The schedule must be applied at the interval (hours or months) that occurs fi rst.




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Engine

Front Axle Hydraulics Linkage Electrical Cab Panels, Decals &

Paint

Filters Cooling Fuel System Clutch Transmission Brakes Rear Axle

Volume 2

Volume 1

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fitting guide for s.44103 full engine · 2016. 1. 15. · 3 these parts are sparex parts and are...

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