John Deere 4010 & 4020 Tractor Service Manual 1960–1972 (P/N SM-2039)

John Deere Service Manual (P/N SM-2039) covers 4010 and 4020 tractors in Row-Crop, Standard, and Hi-Crop configurations, with gasoline, LP-Gas, and diesel engines. It covers 4010 Syncro-Range and 4020 Syncro-Range and Power Shift transmissions, with revision pages dated through April 1967.

PDF Access and Wiring Detail

Search, bookmarks, and diagram detail: Manual text is not searchable. Embedded section bookmarks provide navigation. Small wiring labels need zooming, and some lettering remains soft in enlarged views.

One printable English PDF contains 747 pages, including the cover, one additional front-matter page, 20 blank pages, and one notes page.

Engine, Drivetrain, and Hydraulic Shop Work

The following selected repair topics give a cross-section of the manual. Further subjects include tire ballast and regular and deluxe seat service.

• Engine repair: Step-by-step engine removal and installation, cylinder-head and valve work, liners, pistons, connecting rods, crankshaft, camshaft, governor, crankcase ventilator pump, lubrication, and cooling-system service.

• Fuel-system service: Gasoline and LP-Gas carburetion, LP converter repair, diesel filters and transfer pump, injection-nozzle testing and reconditioning, system bleeding, and injection-pump timing.

• Transmission, clutch, and PTO: Syncro-Range clutch overhaul, shifters, synchronizers, shafts, and gears; Power Shift pressure tests, control valves, C1–C3 and PTO clutches, planetary packs, reduction gears, parking lock, and engine disconnect clutch.

• Hydraulics, steering, and brakes: Closed-center system tests; reservoir, filter, oil cooler, pressure-control and bypass valves; transmission and main-pump service; steering valve, motor, and bleeding; brake valves, cylinders, and disks.

• Implement and chassis repair: Rockshaft, load-control linkage, 3-point hitch, Quik Coupler, selective control valves, breakaway couplers, remote cylinders, Roll-O-Matic, wheel bearings, rear axles, final drives, drawbar, sheet metal, and belt pulley.

• Electrical diagnosis: Ignition, generator, regulator, starter, and battery tests; lighting and instruments; serial-specific wiring diagrams and electrical schematics.

Written for Service Department shop use and training new service personnel, this manual suits trained mechanics and experienced technicians equipped for tractor splitting and component overhaul, including lifting equipment, pressure gauges, electrical test gear, and special tools.

Engine Tests and Diesel Repair Limits

Tune-up coverage includes manifold-vacuum and compression tests, valve-clearance checks, and dynamometer testing. Cooling-system procedures include radiator and pressure-cap testing, thermostat checks, and water-pump disassembly and inspection.

The fuel chapters distinguish Marvel-Schebler and Zenith gasoline carburetors and the Roosa-Master and Scintilla nozzle designs. The diesel chapter covers injection-pump removal, installation, timing, and bleeding.

Full injection-pump bench service—including cleaning, inspection, testing, and calibration—is referred to separate manual SM-2045, which is not included.

Injector-removal cautions explain that prying out a stuck nozzle can distort and damage it.

Transmission Tests and Serial-Specific Repairs

Power Shift diagrams trace power flow in each forward and reverse range. Pressure-test points and fault checks address poor shifting, creep, and torque loss before internal clutch and planetary-pack inspection.

Fuel, electrical, and steering changes: The 4020 material separates fuel-filter, nozzle, battery-connection, wiring, and steering-spindle arrangements at serial 91000. Lamp-harness drawings distinguish the 91000-to-119000 and 119000-and-after groups, helping match the diagrams and procedures to the tractor.

PTO revision: The upper-idler change at 4020 serial 160427 includes revised shaft, gear, thrust washers, lubrication provisions, and AR42533 retrofit information. The Power Shift PTO section warns that a displaced upper-idler-shaft quill can eliminate thrust clearance and cause seizure when the tractor is reassembled.

Hydraulic, Axle, and Diagnostic References

Hydraulic testing covers transmission-pump output, standby pressure, pressure-control valves, selective control valves, and rockshaft leakage. Differential-lock service and separate Hi-Crop final-drive procedures extend the axle coverage beyond the standard planetary final drives.

Named illustrations include Diesel Tractor Electrical System (Two-Wire and Split, or Grounded Circuits), the Power Shift Pump Pressure Test Plug, and the main hydraulic pump's Oil Flow Through Pump. The Exploded View of Steering Motor and Exploded View of Rockshaft Linkage and Control support component identification during overhaul.

Troubleshooting charts cover engine, transmission, clutch, electrical, brake, steering, rockshaft, and remote-cylinder complaints with cross-references to the applicable repair groups.

Specifications, Tooling, and Shop Requirements

Factory tables supply component torque data, fluid capacities, pressure-test specifications, electrical test values, fits, clearances, preload and backlash settings, spring specifications, and new-part dimensions for wear evaluation.

Tool coverage matches fixtures and adapters to jobs: the JDG-2 splitting stand, JDE-52 clutch disk aligning set, JDE-50 nozzle removal and installation kit, and JDH-series hydraulic and steering tools. Applications include diesel compression and nozzle testing, clutch alignment, main-pump seal service, rockshaft and selective-control-valve adjustment, steering repair, and tractor separation.

Many procedures involve heavy castings, tractor separation, and trapped hydraulic pressure. Use proper stands and lifting equipment, support the tractor securely, and relieve system pressure before disassembly.

Examples of Engine Clearances and Nozzle Test Data

For both tractor models, the engine tables list cylinder-liner projection above the block at 0.001–0.004 in. Crankshaft end play with new bearings is 0.0025–0.0085 in.; the maximum allowed with used bearings is 0.0120 in.

Diesel injector data distinguish nozzle opening pressure with a new spring, 2750–2850 psi, from the 2550–2650 psi range after 100 hours. These figures accompany the nozzle inspection and testing material.