2004 John Deere 444J, 544J, 624J Wheel Loader Technical Repair Manual (P/N TM2136)

John Deere technical repair manual TM2136, dated 08JAN04, covers the 2004 444J, 544J, and 624J wheel loaders, with procedures for loader and tool carrier configurations.

Text search and illustration detail: The PDF has searchable text, printed contents pages and an index, but no embedded bookmarks. Some illustration labels are outside the searchable text. Small labels in valve cross-section views are readable when enlarged.

• Transmission and drivetrain: Torque converter removal, input and output shaft service, power shift clutch work, transmission pump repair and hydraulic control valve disassembly.

• Wheels and axles: Wheel and drive shaft removal, axle oscillating support repair, axle disconnect overhaul, differential lock solenoid replacement and axle circulation system illustrations.

• Loader hydraulics and steering: Hydraulic pump and loader control valve service, steering cylinder replacement, boom and bucket cylinder removal, and ride control accumulator repair.

• Brakes and frame: Service brake valve and accumulator replacement, park brake overhaul and bench testing, frame separation and pivot bearing service.

• Engine auxiliary systems: POWERTECH engine removal and installation, serpentine belt replacement, cooling package removal, fuel tank work and dampener drive service.

• Cab and air conditioning: Cab removal, R134a recovery, evacuation and charging, leak testing, compressor clutch service and freeze control switch bench testing.

John Deere wrote this manual for experienced technicians and identifies the essential tools required for the work described.

Transmission Repair and Clutch Pack Differences

The KV/KR disassembly instructions specify complete clutch pack replacement for the 444J and 544J; internal clutch pack repair is described for the 624J. That distinction helps establish whether you need a complete assembly before ordering clutch components.

The transmission sections cover clutch clearances, input shaft assembly and control valve reassembly. The Transmission Hydraulic Control Valve Cross Section View identifies the pressure regulating and reducing valves, modulation circuit and proportional solenoids.

Tool references include JDG1129 transmission mounting brackets and a fabrication drawing for the DFT1149 clutch pack compression ring tool.

Axle Supports, Disconnects and Frame Bearings

Axle oscillating support inspection covers thrust bearing wear, bushing condition and end play; this assembly does not use shims to set end play. The Axle Disconnect Input Shaft, Cross-Sectional View supports disconnect inspection; the Axle Oil Cooler—Exploded View shows the circulation cooling hardware.

Internal TEAMMATE III 1000, 1200 and 1400 planetary axle work and service brake replacement refer to the separate CTM150, which is not included.

Frame repair covers upper and lower pivot bearings, preload shims and seals. Loader and tool carrier sections distinguish their tilt linkages, boom bushings and bucket clearances. The pivot bearing instructions warn that incorrect pressing loads can damage the bearings.

Loader Valves, Cylinders and Ride Control

Valve coverage extends to the boom, bucket and auxiliary sections, load sense relief valve, pilot controls and pressure reducing manifold. The hydraulic pump rotating group is serviced as an assembly; the fan pump is replaced as a complete unit. A DFT1132 hydraulic pump removal tool drawing is included.

Boom and bucket cylinder removal is documented here, while internal repair refers to the separate TM-H120A and TM-H125A manuals, which are not included. The loader and steering cylinder start-up procedures address oil dieseling that can damage internal components after cylinders have been drained or rebuilt.

Ride control coverage includes accumulator piston seals and valve components. System diagnostics, hydraulic pressure tests and accumulator charging refer to TM2135 Operation and Test, which is not included. Electrical wiring diagrams are outside this repair manual's scope.

POWERTECH Engines and Cooling Package

Engine coverage addresses removal and installation of POWERTECH 4.5L (4045) and 6.8L (6068) engines. Internal engine overhaul requires the separate CTM104.

Fuel system references distinguish Level 12 with DE10 pump on the 444J/544J (CTM331) from Level 11 with Denso HPCR on the 624J (CTM220). These component manuals are not included.

Belt routing views show configurations with and without air conditioning. Cooling procedures distinguish hydraulic oil cooler removal on the 444J/544J from the 624J layout.

R134a Service and Workshop References

The air conditioning section includes flushing and purging, component oil charge guidance, heater valve leak checks and compressor clutch clearance adjustment. Its Air Conditioning System Fittings Reference Chart identifies fittings for individual components and the JT02098 flush fitting kit.

Component location views, torque specifications, fluid capacities, wear limits and assembly clearances accompany the relevant repair procedures.

Working on heavy machinery involves inherent crush hazards and high-pressure fluid risks. Follow the manual's precautions for raised equipment, articulation joints, stored hydraulic pressure and refrigerant service.

Printable PDF and Included Pages

The single printable English PDF has 378 pages total: 306 pages of technical content, 16 contents pages, a six-page index, one cover, one foreword, one feedback form, and 47 blank or heading-only pages. The two dealer-tool drawing pages are included in the 306 technical pages.