Husqvarna HUV4420 Service Manual
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Husqvarna HUV4420 Service Manual

Husqvarna HUV4420 Service Manual

Gasoline/diesel vehicles
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  • Page 3 If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Husqvarna advises that all repairs and/ or service be performed by an authorized Husqvarna distributor/dealer representative or by a Husqvarna fac- tory-trained technician.
  • Page 4 • Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed. NOTE: This manual represents the most current information at the time of publication. Husqvarna is con- tinually working to further improve our vehicles and other products. These improvements may affect servicing procedures.
  • Page 5 Front Body Removal ........................Front Body Installation ........................Front Fender Removal ........................Front Fender Installation ....................... Roll-Over Protective Structure (ROPS) .................... ROPS Removal ..........................ROPS Installation ......................... 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page iii...
  • Page 6 Front Brake Pad and Caliper Removal ..................Front Brake Pad and Caliper Installation ..................Rear Brake Pad and Caliper Removal ..................Rear Brake Pad and Caliper Installation ..................Page iv 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 7 Brake Pedal Adjustment ....................... Park Brake Pedal ..........................Park Brake Pedal Removal ......................Park Brake Pedal Installation ......................Park Brake Cable Installation ....................... Park Brake Cable Adjustment ....................... 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page v...
  • Page 8 Tire Removal ..........................Tire Installation ..........................SECTION 9 – REAR SUSPENSION Rear Coil-Over Shock Absorber ....................... Swing Arms ............................Swing Arm Removal ........................Swing Arm Installation ........................Page vi 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 9 SECTION 12A – ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter and Starter Solenoid ......................12a-1 Relays ............................... 12a-1 Neutral Switch ........................... 12a-2 Carburetor Solenoid .......................... 12a-2 Voltage Regulator ..........................12a-3 Instrument Panel ..........................12a-4 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page vii...
  • Page 10 Fan Motor ............................12b-17 Wire Harness Diodes ........................12b-18 Bed Lift Switch ..........................12b-18 Bed Lift Circuit Breaker ........................12b-19 Battery .............................. 12b-20 General Information ........................12b-20 Page viii 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 11 Air Filter Intake Hose Removal ..................... 13a-29 Air Filter Intake Hose Installation ....................13a-30 Air Filter Outlet Hose Removal ..................... 13a-31 Air Filter Outlet Hose Installation ....................13a-31 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page ix...
  • Page 12 Air Filter Intake Hose Removal ..................... 13b-27 Air Filter Intake Hose Installation ....................13b-28 Air Filter Outlet Hose Removal ..................... 13b-29 Air Filter Outlet Hose Installation ....................13b-29 Page x 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 13: Section 14 - Drivetrain Components

    Forward/Reverse Shifter Handle ....................14-18 Rear Differential and Axles ....................... 14-19 Rear Differential Removal ......................14-19 Rear Axle Shafts and Wheel Bearings ..................14-20 Rear Differential Installation ......................14-20 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page xi...
  • Page 14 SECTION 15 – RADIATOR AND COOLANT SYSTEM (DIESEL) General Information .......................... 15-1 Engine Coolant Check ........................15-1 Engine Coolant Change ........................ 15-1 Coolant Reservoir Removal ......................15-3 Coolant Reservoir Installation ....................... 15-4 Radiator ............................15-4 Radiator Removal ......................... 15-4 Radiator Installation ........................15-8 Coolant Pipe Weldment (Steel) ......................
  • Page 15 18-7 Ring Gear Installation ........................18-8 Pinion Gear Installation ......................... 18-9 Rear Differential Assembly ......................18-9 Axle Shafts and Differential Installation .................... 18-10 SECTION i – INDEX 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page xiii...
  • Page 16 Page xiv 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 17: General Warning

    SECTION 1 – SAFETY To ensure the safety of those servicing Husqvarna vehicles, and to protect the vehicles from damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements contained within headings labeled DANGER, WARNING, CAUTION, or NOTE.
  • Page 18 • When servicing the vehicle with part of the vehicle on jack stands, do not operate the engine with the Forward/Reverse handle in either the FORWARD or REVERSE position. The all-wheel drive system will engage any wheel(s) with traction. See Figure 1-1, Page 1-3. Page 1-2 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 19 • Do not leave children unattended on vehicle. TO FUSE BLOCK DIESEL VEHICLE SHOWN Remove negative (–) cable first. TO GROUND Figure 1-2 Battery 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 1-3...

  • Page 21: Section 2 - Vehicle Specifications

    1551 lb. (703.5 kg) Forward speed 25 mph (40 km/h) Governed RPM 3825 3825 Turning radius (per SAE J 695) 141 in. (358 cm) Specifications continued on next page... 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 2-1...
  • Page 22 Fuel tank: diesel grade no.2 with cetane rating of 45 or higher 6.5 gallons (24.6 L) TIRE PRESSURE All-terrain tread 20 - 22 psi (1.38 - 1.52 Bars) Mud tires 20 - 22 psi (1.38 - 1.52 Bars) Page 2-2 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 23: Section 3 - General Information

    NOTE: Have the vehicle serial number available when ordering parts or making inquiries. SERIAL NUMBER DH0501-123456 7349 STATESVILLE RD. CHARLOTTE, NC 28269 Figure 3-1 Vehicle Serial Number 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 3-1...

  • Page 24: Preparing The Vehicle For Extended Storage

    4.3. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 3-2, Page 3-3). 4.4. Plug the fuel tank vent nipple so that it is air tight. Husqvarna recommends using a slip-on vinyl cap. 5. Remove both spark plugs and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes.

  • Page 25: Returning The Stored Vehicle To Service

    6.2. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 3-3, Page 3-3). 6.3. Plug the fuel tank vent nipple so that it is air tight. Husqvarna recommends using a slip-on vinyl cap. 7. Change engine oil. See Engine Oil and Filter Change on page 10-7.
  • Page 26 Figure 3-4 Fuel Shut-Off Valve – Open Position Figure 3-5 Fuel Shut-Off Valve – Closed Position PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 3-6 Fuel Shut-Off Valve – Partially Closed Position Page 3-4 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 27: Section 4 - Body And Trim

    Each vehicle is equipped with an ABS/DR acrylic cap front body and an aluminum rear body and frame. The cargo bed is powder-coated steel. Husqvarna does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water dam- age and subsequent component failure.

  • Page 28: Front Body Repair

    2. Pull the top of the instrument panel forward to access the panel rear. 3. Disconnect the wiring from components mounted on the instrument panel. Page 4-2 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 29 4.8. Feed the cable from the engine compartment, under the body, and up to the dash. 5. Remove the instrument panel. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 4-3...

  • Page 30: Instrument Panel Installation

    5. Advance the park brake release handle to the jam nut, and tighten the nut to 50 in-lb (5.6 N·m). 6. Install the instrument panel. See Instrument Panel Installation on page 4-4. Page 4-4 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 31: Roll-Over Protective Structure (Rops)

    • Do not operate the vehicle if the ROPS is damaged. If the ROPS is damaged, replace the structure. Do not attempt repair. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 4-5...

  • Page 32: Rops Removal

    3. Install the top structure (1, 2, and 3) to the frame seat bars and front frame bars. Install four bolts (4), four washers (6), and four locknuts, and tighten the hardware to 33 ft-lb (45 N·m). See following WARNING. Page 4-6 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 33: Seat Adjustment

    1. Install the seat frame (7) (Figure 4-4, Page 4-6). 2. Secure the seat frame to the seat side plates with bolts, washers, and flanged locknuts. Tighten the hard- ware to 37 ft-lb (50 N·m). 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 4-7...

  • Page 34: Safety Belt Removal

    • Do not insert coins, clips, etc. into the safety belt buckle. Foreign objects may interfere with the buckle locking mechanism. • If the safety belt does not function normally, contact your Husqvarna dealer/distributor or trained technician immediately. Do not occupy the seat until the safety belt is repaired.

  • Page 35: Bed Lift Motor Removal

    NOTE: Do not tighten the loser mounting hardware until the rod end has been secured. 4. Attach the rod end of the bed lift motor to the bed frame bracket. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 4-9...

  • Page 36: Cargo Bed Removal

    2. Install the top Torx-head, self-tapping screw and washer. Tighten the hardware to 50 in-lb (5.6 N·m). 3. Tighten the phillips-head side screws and washers to 13 in-oz (91.8 N·mm). 4. Repeat steps 1 through 3 to install the remaining fender if necessary. Page 4-10 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 37: Floor Mat Removal

    1. Lift the back edge of the floor mat, and slide the front edge down and away from the aluminum mat shield. FLOOR MAT INSTALLATION 1. Slide the mat up and under the aluminum mat shield, and tuck the rear edge down against the seat panel. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 4-11...

  • Page 39: Section 5 - Hydraulic And Park Brake Systems

    • Inspect the exterior of the master cylinder. Replace any leaking components, and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 5-22. • Check the brake fluid level. See Brake Fluid, Section 10, Page 10-6. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-1...
  • Page 40 See Brake Pads and Caliper on page 5-5. Also See Hydraulic Line Replacement on page 5-17. Page 5-2 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 41: Brake System Troubleshooting

    Weak (bulging) brake line Line Replacement on page 5-17. Improperly adjusted master cylinder push See Brake Pedal Adjustment, Section 6, Page 6-4. Troubleshooting Guide continued on next page... 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-3...
  • Page 42 Replace the brake pads See Brake Pads Bent, damaged, or incorrect brake pads scraping sound upon brake application and Caliper on page 5-5. Troubleshooting Guide continued on next page... Page 5-4 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 43: Front Brake Pad And Caliper Removal

    • Prior to servicing hydraulic brakes, thoroughly clean the vehicle, paying particular attention to areas immediately surrounding hydraulic connections, to prevent dirt or debris from entering system. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-5...
  • Page 44 3. Remove the two hex-head bolts that secure the caliper assembly to the upright, and remove the caliper. 4. Repeat steps 1 through 3 for the opposite front wheel if necessary. Page 5-6 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 45: Front Brake Pad And Caliper Installation

    1. Install the brake pads and install the socket-head slide-pin bolts through top and bottom holes of pads. Tighten the hardware to 32 ft-lb (43 N·m). 2. Install the tire and wheel. Finger-tighten the lug nuts. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-7...

  • Page 46: Rear Brake Pad And Caliper Removal

    3. Remove the two hex-head bolts that secure the caliper assembly to the upright, and remove the caliper (Figure 5-5, Page 5-9). 4. Repeat steps 1 through 3 for the opposite rear wheel if necessary. Page 5-8 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 47: Rear Brake Pad And Caliper Installation

    Tighten the hardware to 32 ft-lb (43 N·m). See following NOTE. NOTE: It may be necessary to loosen the park brake adjuster arm on the caliper. 2. Install the tire and wheel, and finger-tighten the lug nuts. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-9...

  • Page 48: Brake Disc And Hub

    4. Remove the axle spindle nut and washer (Figure 5-7, Page 5-10). See following NOTE. NOTE: A new spindle nut will be required during assembly. Figure 5-7 Axle Spindle Nut and Washer Figure 5-8 Brake Caliper and Upright Page 5-10 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 49 10.2. Position the disc (6) and upright (5) between the blocks. 10.3. Place a 2 x 1/4-inch flat steel bar (2) under each of the two tabs on the upright (5) on the steel blocks (1). 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-11...
  • Page 50 12.2. Shim the ball joint arms (2 and 3) with steel blocks to provide a level surface for bearing removal. 12.3. Use a rod or bar (8) slightly smaller than the diameter of the bearing cavity opening (7), and press the bearing out of the upright. Page 5-12 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 51 16. The disc and hub shaft should be approximately 1/16 inch below the bearing inner race surface (Figure 5-16, Page 5-14). 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-13...

  • Page 52: Front Wheel Disc And Hub Installation

    9. Slip the brake pads over the disc, and install the brake caliper and brake pads on the upright with two hex- head bolts. Tighten the bolts to 36 ft-lb (49 N·m). Page 5-14 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 53: Rear Wheel Disc Removal

    8. Remove the rear caliper from the rear axle bracket. Secure the rear caliper to the respective swing arm assembly with wire ties to remove pressure from the fittings and brake line. Figure 5-17 Rear Axle Stand Figure 5-18 Rear Wheel Disc and Hub 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-15...

  • Page 54: Rear Wheel Disc Installation

    11. Tighten the axle nut to 80 ft-lb (108 N·m). Position the locking cap and attach a new cotter pin. 12. Tighten the lug nuts to 65 ft-lb (88 N·m). 13. Repeat steps 1 through 12 for the opposite rear wheel if necessary. Page 5-16 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 55: Front Brake Line Removal

    4. Install the two support brackets, and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 5-20, Page 5-18). 5. Secure the hydraulic lines to the frame above the steering column shaft with wire ties. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-17...

  • Page 56: Rear Brake Line Removal

    3. Remove the front body. See Front Body Removal, Section 4, Page 4-5. 4. Use a flare-nut wrench to remove the rear brake line at the master cylinder. See following NOTE. Page 5-18 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 57: Rear Brake Line Installation

    5. Fill the reservoir of the master cylinder, and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 5-22. 6. Perform all of the brake system inspections. See Brake System Inspection on page 5-1. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-19...

  • Page 58: Master Cylinder And Reservoir

    4. Fill the reservoir with brake fluid specified for this vehicle, and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 5-22. 5. Inspect the brake system. See Brake System Inspection on page 5-1. Page 5-20 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 59: Master Cylinder Removal

    Figure 5-21 Master Cylinder Rod and Brake Pedal 7. Remove the two bolts and lock nuts that secure the master cylinder to the frame. 8. Remove the master cylinder from the vehicle. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-21...

  • Page 60: Master Cylinder Installation

    6.1. Connect an air hose to the vacuum brake bleeder. The air pressure must be regulated at 12 to 15 psi (0.827 to 1.034 Bars). 6.2. Press the handle on the brake bleeder to start the vacuum. Page 5-22 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 61: Purging The Hydraulic System

    6. Inspect the brake system to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspec- tion on page 5-1. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-23...

  • Page 62: Park Brake Cable Adjustment

    6. Move the cable up and toward the rear of the vehicle, and remove the cable from the caliper arm (Figure 5-22, Page 5-25). 7. Disconnect the threaded end of the cable from the frame bracket, and remove the cable (Figure 5-23, Page 5-25). Page 5-24 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 63 Tighten the nuts to 40 ft-lb (54 N·m). 8. Secure the cable to the frame with a wire tie. 9. Secure cable end to the equalizer bracket. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-25...

  • Page 64: Front Park Brake Cable Removal

    3. Remove the nuts from the threaded adjustment rod on the cable end. 4. Remove the rear park brake cables from the equalizer, and remove the equalizer. Page 5-26 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...

  • Page 65: Front Park Brake Cable Installation

    See Brake System Inspection on page 5-1. 9. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-27...
  • Page 66 1. Remove the four bolts, washers, and locknuts that secure the lower pulley assembly to the bottom of the frame under the floorboard. 2. Remove the pulley. Page 5-28 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 67 5. Install the front park brake cable. See Front Park Brake Cable Installation on page 5-27. 6. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4. 7. Install the front body. See Front Body Installation, Section 4, Page 4-5. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 5-29...

  • Page 69: Section 6 - Accelerator And Brake Pedal Assemblies

    8. Inspect the pedal bushings for wear and replace pedal assembly if worn. 9. Inspect the pedal and return spring hub bushings for excessive side-to-side movement. Replace the pedal assembly if either or both show signs of excessive wear. 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 6-1...

  • Page 70: Accelerator Pedal Installation

    NOTE: This process should only take a few seconds. 5. Measure the engine RPM with a tachometer approved for this engine (Husqvarna 603 00 19-22). 6. Release the accelerator pedal, turn the key switch to the OFF position, and remove the key.

  • Page 71: Brake Pedal Installation

    5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (Husqvarna 603 00 00-03). 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 6-3...

  • Page 72: Brake Pedal Adjustment

    Tighten the hardware to 15 ft-lb (20 N·m). 2. Install the cable end on the pedal bracket stud. 3. Install a washer and the brake cable C-clip on the pedal bracket stud. Page 6-4 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual...
  • Page 73 (Figure 6-6, Page 6-5). 4.2. Tighten the jam nut to 55 in-lb (6 N·m). Figure 6-6 Park Brake Adjustment Nuts 2005 HUV4420 Gasoline and HUV4420-D Diesel Vehicle Maintenance and Service Manual Page 6-5...

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