2004–2013 Massey Ferguson 6475, 6480, 6485, 6490, 6495, 6499, 6497, 6470, 6465, 6460, 6455, 6445 Tractor Workshop Service Manual (P/N 3378405M4)

This Massey Ferguson Workshop Service Manual no. 3378405M4 covers 6400 Series models 6445, 6455, 6460, 6465, 6470, 6475, 6480, 6485, 6490, 6495, 6497, and 6499.

The set contains 4,029 pages across 12 PDF files, supplied in a RAR archive. The total includes the cover, contents pages, and blank pages.

• Engine work and tractor splitting: Perkins and Sisu installation procedures, injection-pump and controller replacement, pump timing, and separation of major tractor assemblies.

• Transmission and PTO repair: PowerShuttle, Dynashift, and Powershift service; GBA25 robotic gearbox repair; creeper units; PTO clutch, brake, and shaft work.

• Axles and final drives: GPA20, GPA30, and GPA40 rear-axle repair, plus Carraro, Carraro 20.48, and Dana front-axle service and suspension troubleshooting.

• Hydraulic diagnosis: Open Center, Load Sensing, and Twin Flow Load Sensing pressure and flow tests, pump service, steering repair, and brake-control procedures.

• Electronic troubleshooting: WINTEST procedures, error codes, programming, calibration, and wiring diagrams for engine, transmission, hitch, implement-control, and suspended-front-axle systems.

• Cab and accessories: Pneumatic cab-suspension diagnosis, standard and automatic air-conditioning service, front-linkage hydraulics, and Zuidberg front-PTO repair.

AGCO prepared this manual to assist dealers and agents; its repair depth, service-tool references, and calibration work suit professional technicians or equivalently experienced mechanics with the proper shop equipment.

Perkins and Sisu Engine Scope

The engine volume provides specifications, fuel/oil/coolant standards, EEM/EEM2 controller and injection-pump procedures, pump timing, ECU-to-pump serial-number matching, spacers, and engine/transmission links. It is not a full internal engine overhaul manual for crankshaft, piston, connecting-rod, or cylinder-head rebuilding.

Tractor splitting coverage distinguishes Perkins and Sisu front-frame separation, the dedicated MF 6497-6499 front-frame split, engine-to-gearbox and gearbox-to-center-housing separation, PTO housing removal, GPA30 intermediate-housing work, and GTA1030/GTA1040 reinforcements.

Transmission and PTO Repair

Configuration tables distinguish GBA20/GBA10 Dynashift and GBA25/GBA15 Dyna-6 transmissions. Detailed procedures cover PowerShuttle removal, Dynashift and Powershift module teardown, GBA25 robotic gearbox shaft service, selector-rail and fork adjustment, creeper and Super Creeper units, clutch packs, shaft shimming, PTO brakes, and final operating checks.

GBA15 coverage includes operating descriptions, assembly views, synchronizer inspection, illustrated dismantling stages, and transmission specifications.

The GBA10 mainshaft section warns that incorrect laminated-shim placement can damage the shim stack under load.

Rear and Front Axles

Rear-axle procedures address normal-duty, heavy-duty, sealed heavy-duty, and composite-drive trumpet housings, brake pistons, drive pinions, and five- and seven-inch differential units and locks.

Front-axle work covers final drives, wheel hubs, 4WD clutches, suspension arms, steering geometry, backlash checks, and differential shimming. Carraro differential instructions identify noninterchangeable adjustment nuts and mandatory ring-nut/flexible-spacer replacement; incorrect assembly or reuse can compromise bearing preload and ring-and-pinion backlash.

Hydraulic Tests and Steering

Factory procedures cover pump and hydraulic-cover service, auxiliary valves, hitch control, assisted and trailer brakes, ParkLock, Orbitrol steering, steering rams, and suspended-front-axle control units.

The GBA20 reverse-shuttle hydraulic circuit and GTA1040, GTA2020, and GTA2520 load-sensing diagrams support the separate system-specific tests. This separation helps a mechanic select the hydraulic test procedure that matches the tractor's installed system.

Electronic Diagnostics and Wiring

Coverage includes Perkins EEM and Sisu EEM2 injection, DCC2, Autotronic 3 and 5, EHRC linkage, Datatronic 2 and 3, SMS/FingerTIP, ParkLock, and Carraro/Dana suspension controllers. Test routines, error-code tables, parameter settings, and calibration procedures are organized by controller.

SisuDiesel software-selection tables distinguish the 6485 at N258068/N258069, 6490 at N342061/N342062, 6495 at N344031/N344032, 6497 at N345039/N345040, and 6499 at N307025/N307026. These are software-selection breaks, not overall manual-coverage limits.

Wiring material includes complete Perkins EEM CAN networks, Sisu EEM2 wiring and connector diagrams, and DCC2 Dyna-6/Autotronic 5 schematics with harness parts lists. Carraro and Dana suspended-axle component layouts and automatic air-conditioning diagrams provide further component and connector identification.

Cab, Air Conditioning, and Front Equipment

Cab-suspension material includes pneumatic checks and symptom/cause charts. Air-conditioning sections cover fault diagnosis, leak testing, evacuation, recharging, and pressure checks. The accessories volume adds front-linkage operating modes and Zuidberg front-PTO removal, clutch disassembly, inspection, reassembly, and troubleshooting.

Service Data and Special Tools

Reference material includes model configuration tables, ground speeds, dimensions, fluid capacities, metric and inch fastener torque tables, component-specific tightening data, and sealing products. Repair sections add pressure-test specifications, inspection limits, clearances, shimming data, and electrical test values.

Service-tool references include the 3378225M11 PowerShuttle housing sling, 3376920M2 planet-carrier compression tool, and Carraro CA119030 square-head wrench, plus drawings for locally made fixtures where specified.

Tractor splits, axle and cab support work, and hydraulic testing involve suspended loads and stored pressure. Use the stands, slings, isolation steps, and component-specific torque instructions identified in the manual before disassembly.

PDF Files, Navigation, and Readability

The individual PDF page counts are:

• Introduction and Specifications: 73, including the one-page cover
• Splitting the Tractor: 206
• Engine: 68
• Gearbox: 482
• Rear Axle: 484
• Power Take Off: 262
• Front Axle: 370
• Hydraulics: 622
• Electrical Equipment: 186
• Electronics: 1,150
• Cab and Equipment: 88
• Accessories: 38

Text search and navigation: All 12 files have searchable text and embedded PDF bookmarks for chapters and subsections. The cover and some labels within embedded images are outside the text search.

Wiring readability: The large electrical drawings in Electrical Equipment, Electronics, and Cab and Equipment require zooming to read small pin numbers and wire codes.