This document is the repair manual for the New Holland Rustler 120 Diesel and Rustler 125 Gasoline vehicles. It contains sections on safety, vehicle specifications, body and trim components, accelerators and brake pedals, hydraulic and park brake systems, steering and front suspension, wheels and tires, rear suspension, periodic maintenance, troubleshooting, electrical components, engines, drivetrains, radiators, transmissions, differentials, and more. The manual provides instructions for repairs, removals, installations, adjustments, and inspections of various vehicle systems.

1. New Holland
Rustler 120 Diesel
Rustler 125 Gasoline
REPAIR MANUAL

2. Contents
SAFETY
Safety Details
General Warning
Disabling The Vehicle
Disconnecting The Battery
Connecting The Battery
VEHICLE SPECIFICATIONS
GENERAL INFORMATION
General Information
Model Identification
Identification Numbers
Storage
Preparing the Vehicle for Extended Storage
Returning the Stored Vehicle to Service
Using A Booster Battery (Jump Starting)
BODY AND TRIM
Cleaning the Vehicle
Seat Cleaning
Front Body Repair
Light Scratches
Abrasions and Haze
Large Scratches and Abrasions
Front Body Components
Instrument Panel Removal
Instrument Panel Installation
Front Fascia Removal
Front Fascia Installation
Hood Removal
Hood Installation
Center Cowl Panel Removal
Center Cowl Panel Installation

3. Side Cowl Panel (Fender) Removal
Side Cowl Panel (Fender) Installation
Front Fender Flare Removal
Front Fender Flare Installation
Roll-Over Protective Structure (ROPS)
ROPS Removal
ROPS Installation
Seat
Seat Removal
Seat Adjustment
Seat Installation
Seat Support Removal
Seat Support Installation
Safety Belts
Safety Belt Removal
Safety Belt Installation
Cargo Bed Electric Lift
Testing the Bed Lift Motor
Bed Lift Motor Removal
Bed Lift Motor Installation
Cargo Bed Removal
Cargo Bed Installation
Cargo Bed Manual Lift
Cargo Bed Removal
Cargo Bed Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal and RPM Adjustment
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation

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New Holland Rustler 120 125 Repair Manual
Brake Pedal Adjustment
Park Brake Pedal
Park Brake Pedal Assembly Removal
Park Brake Pedal Assembly Installation
HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection
Brake System Troubleshooting
Brake Pads and Caliper
Front Brake Pad and Caliper Removal
Front Brake Pad and Caliper Installation
Rear Brake Pad and Caliper Removal
Rear Brake Pad and Caliper Installation
Brake Disc and Hub
Front Wheel Disc and Hub Removal
Front Wheel Disc and Hub Installation
Rear Wheel Disc Removal
Rear Wheel Disc Installation
Hydraulic Line Replacement
Front Brake Line Removal
Front Brake Line Installation
Rear Brake Line Removal
Rear Brake Line Installation
Master Cylinder and Reservoir
Filling the Hydraulic System
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Bleeding Brakes on a DOT Fluid Filled System

5. Purging the Hydraulic System
Park Brake System
Park Brake Adjustment At Rear Calipers
Park Brake Cable Adjustment
Park Brake Wheel Cables
Front Park Brake Cable Removal
Front Park Brake Cable Installation
Park Brake Equalizer Removal
Park Brake Equalizer Installation
STEERING AND FRONT SUSPENSION
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Installation
Rack and Pinion Disassembly
Rack and Pinion Assembly
Front Suspension
Wheel Alignment
Front Suspension Components
Steering Upright Removal
Upper A-Arm Removal
Upper A-Arm Installation
Lower A-Arm Removal
Lower A-Arm Installation
Front Coil-Over Shock Absorber Removal
Front Coil-Over Shock Absorber Installation
Steering Upright Installation
WHEELS AND TIRES
General Information
Wheels

6. Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Installation
REAR SUSPENSION
Rear Coil-Over Shock Absorber
Swing Arms
Swing Arm Removal
Swing Arm Installation
PERIODIC MAINTENANCE
Periodic Service Schedule
Periodic Lubrication Schedule
Brake Fluid Reservoir
Brake Fluid
Engine Oil
Oil Pressure Gasoline Engine
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Spark Plugs
Spark Plug Cleaning And Inspection
Spark Plug Gap Inspection
Gearcase Lubrication
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
Lubrication Change for Front Differential, Transmission, and Rear Differential
Engine Coolant Diesel Vehicles
Engine Coolant Level Check
Fueling Instructions
Draining Water from Fuel Filter
Battery
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures

7. Index of Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures
Index of Test Procedures
ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter and Starter Solenoid
Relays
Neutral Switch
Carburetor Solenoid
Carburetor Heater
Voltage Regulator
Warning Lights
Fuel Gauge/Hour Meter
Key Switch
Volt Accessory Receptacle
Bed Lift Switch
Bed Lift Circuit Breaker
Light Switch
Fuse
Reverse Warning Buzzer (If Equipped)
Reverse Warning Buzzer Limit Switch (If Equipped)
Front Differential Limit Switch
Fuel Level Sending Unit
Ignition Coil and Charge Coil
Oil Pressure Sensor
Headlights
Wire Harness Diodes
Battery
General Information
ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid
Relays

8. Neutral Switch
Fuel Solenoid
-Amp Fusible Link
Warning Lights
Fuel Gauge/Hour Meter
Key Switch
-Volt Accessory Receptacle
Bed Lift Switch
Bed Lift Circuit Breaker
Light Switch
Fuse
Reverse Warning Buzzer (If Equipped)
Reverse Warning Buzzer Limit Switch (If Equipped)
Front Differential Limit Switch
Fuel Level Sending Unit
Alternator
Oil Pressure Sensor
Headlights
Thermostat Switch
Fan
Wire Harness Diodes
Battery
General Information
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Gasoline Engine
Engine Removal
Engine Installation
Oil Filter Hoses
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Intermediate Pipe Installation
Muffler Installation
Fuel System
Fuel Lines
Fuel Filter

9. Fuel Pump
Carburetor
Fuel Level Sending Unit
Fuel Tank
Carbon Canister
Fuel Shut-Off Valve
Engine Control Linkages
Accelerator Cable
Choke Cable
Engine Governor Arm
Engine RPM Adjustment
Air Intake System
Air Filter Replacement
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover a-
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine
Engine Removal
Engine Installation
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Manifold Pipe Removal
Manifold Pipe Installation
Intermediate Pipe Installation
Muffler Installation

10. Fuel System
Fuel Lines
Bleeding Air From Fuel System
Fuel Filter Replacement
Fuel Pump
Fuel Level Sending Unit
Fuel Tank
Engine Control Linkages
Accelerator Cable
Engine RPM Adjustment
Air Intake System
Air Filter Replacement
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover
DRIVETRAIN COMPONENTS
Half Shafts
Half Shaft Removal
Half Shaft Installation
Front Differential
Front Differential Removal
Front Differential Installation
Front Driveshaft
Front Driveshaft Removal
Front Driveshaft Installation
Rear Receiver Hitch
Rear Receiver Hitch Removal

11. Rear Receiver Hitch Installation
Rear Axle
Rear Axle Removal
Rear Axle Installation
Rear Driveshaft
Rear Driveshaft Removal
Rear Driveshaft Installation
Transmission
Transmission Removal
Transmission Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Handle
Rear Differential and Axle Shafts
Rear Differential and Axle Shaft Removal
Rear Differential and Axle Shaft Installation
Rear Wheel Bearings
RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information
Engine Coolant Level Check
Engine Coolant Change
Coolant Reservoir
Coolant Reservoir Removal
Coolant Reservoir Installation
Radiator
Radiator Removal
Radiator Installation
Coolant Pipe Weldment
Coolant Pipe Weldment Removal
Coolant Pipe Weldment Installation
Fan
Fan Removal
Fan Installation
TRANSMISSION
General Information
Service Fixture

12. Transmission Removal
Transmission Disassembly
Input Shaft Disassembly
Input Shaft Assembly
Intermediate Shaft Disassembly
Output Shaft Disassembly
Shifter Shaft Removal
Shifter Shaft Installation
Case Inspection
Shaft Seal Removal
Shaft Seal Installation
Output Shaft Assembly
Intermediate Shaft Assembly
Intermediate and Output Shaft Assembly
Transmission Assembly
Transmission Installation
FRONT DIFFERENTIAL
General Information
Axle Half Shaft Removal
Front Differential Removal
Tools Required For This Section
Front Differential Coil And Output Cover
Coil and Output Cover Removal
Coil and Output Cover Installation
Front Differential
Front Differential Disassembly
Front Differential Assembly
Front Differential Installation
Axle Half Shaft Installation
REAR DIFFERENTIAL
General Information
Axle Shafts and Differential Removal
Rear Differential Disassembly
Pinion Gear Removal
Ring Gear Removal

13. Clutch Carrier
Clutch Components
Ring Gear Installation
Pinion Gear Installation
Rear Differential Assembly
Axle Shafts and Differential Installation
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New Holland Rustler 120 125 Repair Manual