Description

Funk 1200, 1400, 1600 2004 Technical Manual

You have a Funk axle on the bench and a stack of aftermarket junk that doesn’t list the right shim thickness or torque sequence. I’ve been wrenching for 28 years, and I can tell you right now — guessing on an inboard planetary will cost you a housing or a differential. This Funk 1200, 1400, 1600 2004 Technical Manual is the real deal: factory-issued, 366 pages, published by Funk Manufacturing Company on 26JUL04. It is the OEM document, not a reprint from some third party who thinks a torque value is “hand tight.” If you want to rebuild one of these axles without making a paperweight, this is what you need.

I have used the earlier CTM43 dated 09JAN98, and this 2004 revision fixes several shim-pack errors in the input housing section. The manual covers all three series — 1200, 1400, and 1600 — and the safety section alone is worth the access. Page 2 has the foreword that tells you exactly what tools are “essential or recommended” for each job. Do not skip that page. I have seen techs get hurt because they ignored the “Avoid High-Pressure Fluids” warning. Page 3 lists the full Contents, so you can jump straight to the group you need: Oscillation Supports, End Play Adjustment, Input Housing — it is all there.

Safety Section: More Than a Warning Sticker

Group 05 opens with a full Safety section. “Prepare for Emergencies,” “Support Machine Properly,” “Avoid Harmful Asbestos Dust” — these are not generic disclaimers. The manual tells you to use proper lifting equipment and to remove paint before welding. It also covers dealer-made tools and how to construct them safely. If you work alone in a home garage, pay attention to the “Work in Clean Area” instruction. A stray chip in the planetary gears will wipe out the entire carrier. The manual also includes a “Dispose of Waste Properly” note that keeps you legal with EPA regs. I have had to tell more than one DIYer that their used gear oil is not drainable down the storm drain. This manual covers that.

General Specifications and Torque Charts

After safety, the General section gives you the “General Inboard Planetary Axle Specifications — OEM Applications.” That is where you find the serial number plates for John Deere applications and OEM applications for 1200, 1400, and 1600 series. The “Metric Bolt and Cap Screw Torque Values” table and the “Unified Inch Bolt and Cap Screw Torque Values — Grade 180” table are right there. No guessing. The manual also has a “Sealants and Adhesives Cross-Reference Chart” — that saved my neck on a helical spline input housing where the thread locker spec was critical. And the oil capacity tables: “Standard and Extreme Duty Axle” and “Super Wide Extreme Duty Axle” — approximate capacities in quarts. Overfill a super wide axle and you get aeration. Underfill and you starve the planetary. The manual tells you how to check, drain, and refill correctly.

Oscillation Support Rebuild: 1200-1400 vs 1600

The manual splits the oscillation support procedures into two groups: one for 1200-1400 and a separate one for 1600. That matters because the 1600 uses an input quill with a different cross-section. For the 1200-1400, you get exploded views of the dual input oscillating supports and step-by-step disassembly, inspection, and assembly. The “Essential or Recommended Tools” list includes a specific puller — do not try to get by with a pickle fork. The 1600 section adds the pivot pin removal and installation procedure. I have done pivot pin replacements on 1600 axles where the pin was seized — the manual’s instructions on heating the housing (following the “Remove Paint Before Welding or Heating” rule) are what kept me from cracking the casting.

Axle Assembly End Play — Why the Specs Matter

End play adjustment is the single most overlooked step on these axles. The manual gives a “Specifications” table with the acceptable end play range, and a procedure to “Adjust Axle Assembly End Play — In Vehicle.” That is a big deal: you do not have to pull the whole axle to set end play. The procedure involves a dial indicator and a specific sequence of shim removal. I have seen axles come in with 0.030 inch of end play because a previous shop thought “a little slop is fine.” The manual says otherwise — and it gives you the exact shim locations from the cross-sectional views. Ignore that and you will get seal leaks and bearing brinelling.

Input Housing Procedures: 1200, 1400, 1600

The manual dedicates separate groups to each series’ input housing. For the 1200-1400 non-helical input spline axle, you get the “Determine Differential Drive Shaft Cone Point Shim Pack” step. That is a math-based shim selection using the cone point distance — if you do not have the factory procedure, you will guess and end up with excessive backlash. The 1400 helical input spline housing has different shim requirements. The 1600 input housing/case cover group includes “Install Axle in Repair Stand” as a first step — that is not a tip, it is a requirement. The manual lists the exact tool part numbers for the repair stand adapter. Skip it and you risk the axle tipping off the bench. I have seen it happen.

Frequently Asked Questions

Is this manual for both the 1200 and the 1600 series?

Yes. The manual covers all three series: 1200, 1400, and 1600. Each has its own section with separate specs and procedures.

Does it include torque values for metric and inch bolts?

It includes a full torque specification chart for metric bolts and cap screws, plus two charts for unified inch bolts (standard grade and Grade 180).

Can I use this manual if my axle is installed in a non-John Deere machine?

Yes. The General section includes serial number plates for OEM applications (1200, 1400, 1600 series) and for John Deere. You identify your axle by the serial number, then follow the applicable procedure. The manual does not care what brand of vehicle the axle is bolted to — the repair steps are the same.

How do I adjust input pinion shaft end play on a 1400 helical spline housing?

The procedure is in the “Adjust Input Pinion Shaft End Play” subsection under the 1400 Helical Input Spline Input Housing group. You need the tools listed in “Essential or Recommended Tools” — specifically a pinion bearing preload adaptor and a dial indicator with a magnetic base. The manual walks you through measuring backface, selecting shims from the provided chart, assembling the housing with the correct sealant (refer to the Sealants and Adhesives Cross-Reference Chart), and torquing the bearing cap bolts to the value in the torque tables. After assembly, you rotate the pinion to seat the bearings, then check preload: 15-25 in-lb for new bearings. I have done this procedure on three 1400 axles in the last month — the manual’s cone point formula is spot-on if you measure the differential drive shaft correctly. Do not skip the “Continue Assembly” steps; they include the o-ring installation order that prevents internal leaks.

If you are rebuilding a Funk TeamMate II axle, this 2004 Technical Manual is the only document you should trust. The OEM torque specs, the safety warnings, and the proprietary shim procedures are not available in any aftermarket compilation. I have the Funk Power DF Series 150/250 Transmissions CTM84 Manual on my shelf too, and it follows the same format — clear, no fluff, no reprints. For other heavy equipment manuals, check the Drogobych Crane КТА-16, КТА-25, КТА-28 2004 Installation Manual or the Injectocean Diablo, Murciélago, Defender, Discovery, Freelander Technical Manual. Need background on driveline theory? See the Manual Transmission article for basics, and for clutch integration, the Manual Transmission section in your vehicle manual will help. Access the Factory Manual and get the axle back under the machine — correctly torqued and safely assembled.