TM2136 2004 Edition: Comprehensive 444J, 544J, 624J Loader Repair Manual (2004)
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Sample pages from the TM2136 2004 Edition: Comprehensive 444J, 544J, 624J Loader Repair Manual (2004) manual
Purchase Information
2004 John Deere 444J, 544J, 624J Loader Repair Technical Manual - Technical Specifications
- Document Number / Seller:
- 27545 / Margaret Moore
- File Size:
- 7.88 MB
- File Type:
- Language:
- English
- Pages:
- 378
- Printable:
- Yes
- Estimated Download Time:
- 0.16 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Wheel Loader
- Brand:
- John Deere
- Reviewed and Approved:
- Jul 10, 2025
John Deere Models and Parts Covered in this Wheel Loader Manual
- 444J (2004)
- 544J (2004)
- 624J (2004)
- 444H (2004)
- 544H (2004)
- 644J (2004)
- 4045 PowerTech (2004)
- 6068 PowerTech (2004)
- 1000 Series TeamMate III (2004)
- 1200 Series TeamMate III (2004)
- 1400 Series TeamMate III (2004)
Complete Manual Information
2004 Edition: John Deere 444J, 544J, 624J Loader Repair Technical Manual
Maximize the uptime and performance of your heavy equipment with the definitive 2004 edition of the John Deere 444J, 544J, and 624J Loader Repair Technical Manual (TM2136). This is not just a basic guide; it is the complete, high-level technical resource used by professional dealership technicians to perform deep-level repairs, component overhauls, and complex system troubleshooting.
Whether you are managing a single unit or a professional fleet, this manual provides the exact specifications and step-by-step procedures required to maintain the structural integrity and mechanical efficiency of your loaders.
Models Covered in This Manual:
- 444J Loader (2004): Specifically detailing the 4045 PowerTech engine configurations and 1000 Series TeamMate III axles.
- 544J Loader (2004): Featuring deep-dive repair data for the 6068 PowerTech engine and 1200 Series TeamMate III axles.
- 624J Loader (2004): Covering the heavy-duty 6068 PowerTech engine setups and 1400 Series TeamMate III axles.
Advanced Technical Content:
- TeamMate III Inboard Planetary Axles: Detailed service for the 1000, 1200, and 1400 Series axles, including axle disconnect input shaft overhauls and specific torque values (e.g., 675 Nm for axle mounting).
- PowerTech Engine Integration: Complete removal and installation procedures for the 4.5L (4045) and 6.8L (6068) diesel engines, including the Level 11 (Denso HPCR) and Level 12 (DE10 Pump) electronic fuel systems.
- Precision Transmission Repair: Covers the full teardown of the Power Shift Clutch, torque converter housing, and the complex hydraulic control valve assemblies. Includes precise specifications like the 504 kg (1110 lb) transmission weight for safe handling.
- Hydraulic & Steering Logic: Comprehensive breakdown of the load-sensing relief valves, steering cylinders, and the pilot control valve system.
- Operator Station & Electronics: Detailed instructions for cab removal (approx. 771 kg / 1700 lb), climate control (R134a) system servicing, and electrical harness routing.
Engineering Specifications & Serial Numbers:
This manual is organized for precision, providing vital data to ensure your repairs meet OEM standards:
- Serial Number Identification: Instructions for locating and identifying serial number plates for the machine, engine, and axles to ensure correct parts ordering.
- Component Weights for Rigging: Includes specific weights such as the 444J Front Axle (920 kg / 2029 lb) and the 624J Front Axle (1280 kg / 2822 lb) to ensure safety during removal.
- Torque & Capacity Charts: Detailed fluid capacities, such as the 25 L (26 qt) differential capacity for the 624J, and critical torque specs for drive shaft universal joints (45 Nm to 78 Nm depending on model).
What You’ll Find Inside:
- Safety Systems: ROPS maintenance, high-pressure fluid precautions, and battery safety.
- Wheels & Fasteners: Tire mounting/demounting and 620 Nm wheel retainer torque specs.
- Axle Systems: Oscillating support repair, thrust bearing tolerances, and oil cooler disassembly.
- Power Train: Multi-clutch pack (KV and KR) assembly and mid-gear speed sensor calibration.
- Engine Auxiliary Systems: Serpentine belt routing (with and without A/C), radiator removal, and intercooler servicing.
- Loader-Specific Frames: Bucket linkage bushing replacement and bell crank shimming procedures.
- Dealer Fabricated Tools: Blueprints for making your own specialty tools like the DFT1132 Hydraulic Pump Removal tool.
Engineered for mobile access and shop-floor use, this manual ensures you have the informative, unique, and specific technical data needed to solve the toughest mechanical challenges on your John Deere J-Series loaders.
Download Instructions for John Deere Wheel Loader Manual
Frequently Asked Questions - John Deere Wheel Loader Manual
What does this John Deere manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for TM2136 2004 Edition: Comprehensive 444J, 544J, 624J Loader Repair Manual (2004). It includes information for the following models: - 444J (2004) - 544J (2004) - 624J (2004) - 444H (2004) - 544H (2004) - 644J (2004) - 4045 PowerTech (2004) - 6068 PowerTech (2004) - 1000 Series TeamMate III (2004) - 1200 Series TeamMate III (2004) - 1400 Series TeamMate III (2004).
Is this manual suitable for beginners?
Yes, this John Deere manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Wheel Loader maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (7.88 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your John Deere Wheel Loader manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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