Tecumseh Parts | Tecumseh Parts Lookup | Tecumseh Repair Manuals
®
This manual covers all Tecumseh Peerless gear products as follows:
T E C H N I C I A N ' S H A N D B O O K
100 Series Differentials
915/940 Series Transaxles
920 Series Transaxles
930 Series Transaxles
1000/1100 Series Right Angle/T-Drives
1200 Series Transaxles
1300 Series Transaxles
2300 Series Transaxles
2400 Series Transaxles
2500 Series Transaxles
2600 Series Transaxles
VST Transaxles
MST200 Series Transaxles
3
6
6
7
7
8
8
9
9
00 Series Transaxles
00 Series Transaxles
01 Slow Speed Transaxle
00 Series Transmissions
00H Series Transmissions
00/801 Series Transaxles
20 Series Transmissions
00 Series Transaxles
10 Series Transaxles
Other illustrated Tecumseh 2-Cycle Engine, 4-Cycle Engine and
Transmission manuals; booklets; and wall charts are available
through Tecumseh.
TECUMSEH & PEERLESS
TRANSMISSION and DRIVE PRODUCTS
For complete listing write or call
ENGINES & TRANSMISSIONS
7
40045
TecumsehProductsCompany
Engine&TransmissionGroup
Tecumseh Europa S.p.A.
Strada delle Cacce, 99
10135 Torino, Italy
9
00 North Street
ENGINES & TRANSMISSIONS
Grafton, WI 53024
Phone: 262-377-2700
FAX: 262-377-4485
Tel. 011 39 11 391-8411
Telefax 011 39 11 3910031
www.TecumsehPower.com
Form No. 691218 R 3/02
Litho in U.S.A.
IMPORTANT NOTICE!
SAFETY DEFINITIONS
Statements in this manual preceded by the following words
are of special significance:
or
WARNING indicates a potentially hazardous situation which
if not avoided, could result in death or serious injury.
NOTE
Refers to important information and is placed in italic type.
It is recommended that you take special notice of all items
discussed on each page and wear the appropriate safety
equipment.
TABLE OF CONTENTS
Page
CHAPTER 1
Model Overview and Terms Used...................................................................................... 1 - 6
Lubrication Chart .....................................................................................................................7
Torque Values Chart ................................................................................................................8
Identification.............................................................................................................................9
Trouble Shooting Table ...................................................................................................10 - 12
CHAPTER 2
00 Series Transaxles.......................................................................................................... 13
CHAPTER 3
3
6
00 Series Transaxles................................................................................................... 14 - 18
01 Slow Speed Transaxle................................................................................................... 19
6
CHAPTER 4
7
00 Series In-Line Shift Transmission............................................................................21 - 25
00H Series Transmissions ...........................................................................................26 - 29
7
CHAPTER 5
8
00/801 Series Transaxles.............................................................................................30 - 36
20 Series Transaxles....................................................................................................37 - 41
8
CHAPTER 6
900 Series Transaxles................................................................................................... 42 - 46
CHAPTER 7
910 Series Transaxles....................................................................................................47 - 50
CHAPTER 8
915 Series / 940 Series Transaxles ...............................................................................51 - 55
CHAPTER 9
9
20 Series Transaxles....................................................................................................56 - 60
CHAPTER 10
9
30 Series Transaxles....................................................................................................61 - 65
CHAPTER 11
MST200 Series Transaxles ............................................................................................66 - 70
Checking Oil Level.................................................................................................................71
CHAPTER 12
200 Series Three-Speed Transaxles............................................................................72 - 74
1
CHAPTER 13
1
300 Series Hydrostatic Gear Reduction Differentials ...................................................75 - 77
CHAPTER 14
2
300 Series Four-Speed Transaxles..............................................................................78 - 84
CHAPTER 15
2
400 Series Hydro Powered Transaxles ........................................................................85 - 87
CHAPTER 16
2
500 Series Hydro Powered Transaxles ........................................................................88 - 92
CHAPTER 17
2600 Series Hydro Powered Transaxles ........................................................................93 - 97
CHAPTER 18
Differentials ..................................................................................................................98 - 103
CHAPTER 19
Drives .........................................................................................................................104 - 108
CHAPTER 20
1
100 Series Drives ..................................................................................................... 109 - 113
CHAPTER 21
Shifting Assembly....................................................................................................... 114 - 116
Shift Key Quick Reference Guide........................................................................................ 117
CHAPTER 22
Bearing and Bushing Service ..................................................................................... 118 - 119
CHAPTER 23
VST Troubleshooting ..................................................................................................120 - 121
C
Tecumseh Products Company
002
2
CHAPTER 1. MODEL OVERVIEW AND TERMS USED
TECUMSEH/TRANSMISSIONS UNITS
900 Series This unit is similar to the 800 series transaxle
with the added feature of 2, 3, or 4 speeds forward
and 1 reverse.
GENERAL
Manufactured since 1945, Tecumseh/Peerless gear
products are found in many products worldwide.
Applications vary from industrial products to residential
and commercial lawn and garden equipment.
9
10 Series The 910 series transaxle offers a forward
and reverse unit. The speed changes with the use of a
variable-drive pulley arrangement.
9
15/940 Series This unit has 3 to 5 speeds forward
This book is intended for use by properly trained
technicians that have appropriate facilities and the proper
tools. If you are not a Tecumseh trained technician, DO
NOT attempt a repair. Consult an Authorized Tecumseh
Servicing Dealer.
and 1 reverse. Reverse is gear driven instead of chain
driven and the case is contoured around the gears.
920 Series The 920 series offers 3 to 7 speeds forward
and 1 reverse. The shifter/brake shaft is similar to the
8
00 series shifter/brake shaft.
IDENTIFICATION OF MODELS
All units manufactured since 1964 have identification
numbers located on an attached tag or are stamped
into the case. This information is required to obtain parts
or replacement units. We have included illustrations on
page 9 of this book to assist you in locating them.
930 Series This unit has 3 to 7 speeds forward and 1
reverse. The transaxle is very similar to the 920 series
except the differential and shifter/brake shaft are different.
The MST Series The MST (Manual Shift Transaxle)
is a sealed unit which uses 16 oz. (473 ml) of 80W90
gear lube (part #730229B). The MST series is available
with up to 6 speeds forward and one reverse and has
a contoured case and cover.
TRANSAXLES
The term transaxle is a combination transmission and
differential in one case. Tecumseh transmissions and
transaxles are manufactured in many different gear
ratio combinations from one to seven forward speeds
with one reverse.
1
200 Series The distinguishing feature of the 1200
series transaxle is that the axle support housings are
pressed in from the inside of the case and cover. Therefore
they are not readily removable until the unit is completely
disassembled. The case is cast iron for rugged, longtime
use.
6
00 Series The 600 series is a lightweight transaxle
used in riding mowers or similar applications. The 600
series has a vertical input shaft at the top of the aluminum
case. Variations in the series (which determine the
specific model number such as 603, 603A, 609 etc.)
include:
2
300 Series Generally similar to the 1200 series
transaxle. The distinguishing features are a more massive
case and a larger shift lever opening machined area.
The obvious difference from the standpoint of application
is that these units have four speeds forward and will
be found on equipment that can be used with ground
engagement operations.
1.
2.
3.
4.
5.
Shift lever shape.
Axle lengths.
Axle machining for wheel hub attachment.
Axle housing variations.
Size of the brake shaft.
NOTE: The 1200 and 2300 series transaxles are fairly
similar in appearance, but do have recognizable
characteristics. Both of these units have cast iron
cases for rugged applications, although the 2300
series is the only unit that can be used with ground
engaging applications.
There may be other slight differences, however, these
are present as a result of product improvement which
are not options to an O.E.M. (Original Equipment
Manufacturer).
8
00 Series This unit has 3 to 6 speeds forward and 1
reverse. This transaxle features bronze oil impregnated
bushings with needle bearings or ball bearings on the
axles, input and output shafts.
8
20 Series With 2 to 6 speeds forward and 1 reverse,
this transaxle is built for heavy duty applications including
use with ground engaging attachments. Sleeved needle
bearings are used in place of oil impregnated bushings
on all shaft ends and ball bearings are standard on
the axles. The 820 also features steel cut gears for
maximum durability.
1
HYDROSTATIC GEAR REDUCTION AND
DIFFERENTIAL UNITS
Right Angle Drives These units consist of input shafts,
output shafts, and the beveled gearing necessary to
change the direction of power at right angles. If the
bevel gear (drive gear) on the input shaft is turned around
and moved to the other side of the case (opposite end
of the shaft), the output shaft will rotate in the opposite
direction.
GENERAL
These units do not have a transmission function
characteristic of transaxles, but rather, are designed
to reduce input speed to a suitable axle speed and
torque range. The hydrostatic units which mate to these
units perform the transmission function.
A cover identifies each unit as being either a left hand
(
LH) or a right hand (RH) right angle drive. The cases
and bearings are identical in both drives.
1
300 Series This unit is the hydrostatic counterpart
of the three-speed forward unit (1200). It has an aluminum
casing and pressed-through axle support housings,
which is characteristic of the 1200 series. The
“
T” Drives The “T” drive is essentially the same as
the right angle drive except that the input shaft extends
out the other side of the case to transmit power in the
same line to additional right angle drives or other
equipment.
®
hydrostatic pump is made by Eaton Manufacturing
and is not serviced by Tecumseh Service Dealers.
2
400, 2500 & 2600 Series This series of hydrostatically
Shafts, Couplings, Pulleys, etc. These items are
part of complete units and are used to connect angle
drives, and other attachments. The serrated couplings
match the serrations on the shafts of the angle drives
and connecting shafts.
driven reduction gear and differential units can be used
in ground engaging operations such as plowing. The
®
hydrostatic pump is manufactured by Sundstrand Corp.
TRANSMISSIONS
Transmissions manufactured by Tecumseh consist of
a shifting mechanism to take a constant input shaft
speed and reduce it to the desired output speed.
Transmissions need a belt drive or chain drive/differential
assembly to deliver power to the wheels.
TERMS USED
AXLE - The shaft which connects the wheel or hub to
the differential unit and transmits force back to the
wheels.
7
00 Series This unit can be 2, 3, 4, 5 & 6 speeds
forward and 1 reverse. The brake system can be mounted
on either side of the unit.
AXLE HOUSING (or AXLE SUPPORT) - An extension
of the case and cover to support the outer ends of the
axles. Because the housing is visible, it is often the
best means of distinguishing the series in question.
7
00 “H” Series This unit is built with almost all
interchangeable parts within its two cases except with
an “H” shift pattern. This unit has 3 or 4 speeds forward
and 1 reverse.
BEARING BLOCK (Strip) - Used to support the ring
gear of the differential.
DIFFERENTIALS
BEVEL (on a gear) This is a chamfer or roundness of
the meshing side of the gear teeth to permit easy
shifting. For instance, with "H" shift pattern transaxles,
this is about the only allowance that can be made to
make shifting easier. Input power should be stopped
before shifting to keep these spur gears from developing
wear.
The 100 series is a self-contained differential/axle unit.
It features hardened or non-hardened axle shafts of
various lengths and is machined with many variations
for hub attachment. The case is cast aluminum and
the differential gears are sintered metal (powdered metal)
or cut steel. The differential pin is held in place by the
four retaining cap screws. Oil Lite bushings reduce
friction during differential operation. The drive sprocket
is part of the unit which, depending upon the application,
can be of several diameters in size thus having a different
number of gear teeth. This sprocket is often supplied
by the O.E.M.
BEVEL GEAR - A gear with teeth ground on a diagonal
so that when it meshes with a second bevel gear, power
o
is transmitted at an angle. If the angle is 90 , the gear
is known as a MITER GEAR.
BEVEL PINION - The smaller of two meshed bevel
gears in a gear train.
ANGLE DRIVES
These units are used primarily to change the direction
of drive at the point where the working equipment
attaches. They can be assembled for right or left hand
rotation so that they can be used in various
combinations for synchronous operation.
BRAKESHAFT/SHIFTER BRAKESHAFT) - The shaft
on a unit (Transaxles or Transmission) to which a braking
system may be attached. It is usually larger in diameter
than the input shaft due to its function of taking shock
loads experienced in braking.
2
CASE - That bottom half of the gear box which contains
the shift lever , axle and brake shaft openings. The
other half is the COVER. Unit reassembly is normally
done into the case with variations listed by individual
model.
INPUT OR INPUT SHAFT - The part of a unit which is
always connected to the drive. Its rotational speed is
dependent on the driving mechanism. The input shaft
brings power to the unit.
LIMITED SLIP DIFFERENTIAL - See DUO-
CHAMFER - In gear products, chamfers provide two
main functions. The first is to reduce gear wear at the
leading contact point as two gears mate. The second
purpose is to act as a ramp for shifter key compression
through the shift washer prior to gear engagement.
The chamfer in the washer is either stamped or
machined in.
TRAK™ DIFFERENTIAL.
MITER GEAR - One of a pair of interchangeable bevel
gears with axles at right angles. Since all bevel gears
are miter gears, the terms can be the same.
MODEL NUMBER - The identifying number of a unit
which will permit selection of the proper parts to repair
that unit.
COUNTERSHAFT - A splined shaft which hold spur
gears that are in constant mesh with shift gears and
transfer input power to the shift gears.
NEUTRAL SPACER - A single or split collar between
forward and reverse gears that the shift keys engage
into when the unit is in neutral.
COUPLING - A sleeve to connect two serrated or splined
shafts in the same axial plane. Used in right angle
drive systems, 700 series, output shafts or in a
hydrostatic drive connecting the pump and motor to
the gear drive of a transaxle.
OIL SEAL, SINGLE LIP/DOUBLE LIP - An oil seal
with one or two sealing surfaces to prevent entrance
of foreign matter and leakage of lubricant.
OIL SEAL, (SQUARE CUT O-RING)- A seal with two
external and two internal sealing surfaces. Used in
the shifter housing.
COVER - The top half of a horizontally parting gear
box such as 700,800,900 and MST models. The cover
normally contains the input shaft, bearing(s) and the
input bevel gear. The shaft may change location in
the cover based on the OEMs mounting position.
OUTPUT, OR OUTPUT SHAFT - On a transaxle, the
shaft that contains the output pinion which is in direct
mesh with and drives the differential. The output shaft
on a transmission contains the sprocket for driving
the axles. The output shaft is driven by the large OUTPUT
GEAR.
DIFFERENTIAL GEAR BOLTS - Through bolts holding
the differential parts together. The heads of these bolts
must be opposite the output shaft gear (except in the
2
400 series). This is an early check to see that the
unit is being assembled correctly.
OUTPUT SHAFT GEAR - The importance of defining
this gear is to point out that it must be opposite the
differential bull gear (except the 2400 series).
DOWEL PIN - An alignment pin used to align the case
and cover and other parts in a transmission or transaxle.
The dowel pins should be installed to hold the parts in
alignment before tightening the retaining screws. Failure
to install dowel pins first will usually lead to a unit that
binds after assembly.
GEAR REDUCTION AND DIFFERENTIAL UNIT - A
unit that reduces a high R.P.M. input speed to a suitable
axle speed without the use of a transmission. Since
there is a single gear train, there is a single input
speed to output speed ratio, however, axle speeds
are infinite, depending upon input speed.
DUO-TRAK™ DIFFERENTIAL (Trademark -Illinois
Tool Works) - A type of differential which increases
torque to the tractive wheel to keep it turning. However
in situations where differentiation is necessary (as in
turning), the unit acts much like a regular differential.
REVERSE IDLER (915 Series) - The gear located
between the reverse gear of the countershaft and the
reverse gear of the shifter/brake shaft that allows the
drive to operate in the opposite direction.
EQUIPMENT - The complete assembled product (riding
mower, tractor etc.) which uses of the drives listed in
this manual.
REVERSE IDLER - A gear added to the gear train so
when in mesh, the direction of all gears driven after it
is reversed. Its number of teeth also affects the reverse
gear ratio. The center gear of the three gear cluster is
always in mesh with the REVERSE IDLER, and the
large shifter gear always shifts into it.
HEAD ASSEMBLY - A complete unit containing all
parts of one right angle or “T” drive assembly of a right
angle drive system. The head assembly is permanently
lubricated and sealed.
RIGHT ANGLE DRIVE / HEAD ASSEMBLY. The major
operating parts are a pair of miter gears. The assembly
consists of other right angle or “T” drive head assemblies
and connecting hardware.
IDENTIFICATION NUMBER - See MODEL NUMBER
IDLER - A gear used in a gear train to transfer motion
or direction. The gear rotates independently of the shaft
upon which it is located.
3
SEAL - A material which prevents lubricant from leaking
SHIFTER HOUSING (600/2300's) - This housing
contains the shift lever and must be re-installed in the
proper position to function correctly. If the housing does
not already have guide marks, scribe the shifter housing
and transmission case before removal.
past a rotating shaft. It can be a rubber or square cut
"
O"-ring, a sealing-type ball bearing, or most commonly,
a rubber sealing surface encased in a metal form.
SEAL RETAINER - Found on some models of transaxles
and on right angle drives.
SHIFTER ROD - One of two similar smooth rods of
equal length with grooves which match the fork
positioning with meshed positions of the shifter gears
and those of the three gear cluster. Each rod has a
snap ring to act as a fork stop, but can also be used
to determine how the fork is assembled to it.
SHIFT COLLAR - A round collar which retains shift
keys onto the shifter/brake shaft. The shifter assembly
pin (or pins) slide into the groove on the collar to move
the shift keys.
SHIFT GEARS - The gears on the shifter/brake shaft
that are in constant mesh with the spur gears of the
counter shaft. The shift gear is engaged by the shift
keys and it's size determines the speed of output by
the axles.
SHIFTER SHAFT - A splined shaft which meshes with
the internal splines of the shifter gears, to transmit
force to the output shaft gear. On in-line transmissions
and transaxles the shaft has machined channels to
accommodate the shift keys.
SHIFT KEY - One of either two or four metal spring
steel keys, which are held in the keyways of the shifter/
brake shaft by a shift collar. The shift keys are used
to slide through the shift gears and engage the desired
gear or speed.
SHIFTER STOP (600/2300's) - A stamped metal plate
which separates the shifter forks. The stop has a notch
cut in it which corresponds to the neutral position on
the shifter forks and rod. The shifter lever must return
the engaged fork back to neutral before it can actuate
the other fork.
SHIFT KEYWAY - One of either two or four slots in
the shifter/brake shaft for the shift keys to slide through
for gear selection.
SPROCKET - A geared wheel designed to turn a chain
drive. Sprocket diameters vary and are available in
different sizes for changing output ratios.
SHIFT WASHER - The shift washer provides a ramp
to gradually compress the shift key prior to engagement
with the gear. We have used two types in production;
the newer style has the chamfer stamped into the
washer. Earlier production washer’s had the chamfer
machined in.
SPUR GEAR - A gear having the shaft bore and teeth
in a parallel plane.
“T” DRIVE - A right angle drive with an input shaft
extending thru the case to transmit power axially in a
second direction to the right angle output. On “T” drives
with dissimilar input and output ends, care must be
taken to insure that the parts do not run in reverse
when reassembled.
SHIFTER ASSEMBLY - Consists of a shift rod, shift
fan, shift arms and shift pin or pins.
SHIFT LEVER - The lever by which the operator manually
changes the shifter gears to vary reduction speed ratios
in the transmission. The configuration of the lever is
variable and is often the only reason for a unit being
given a new model number.
THREE GEAR CLUSTER (2300) - A three gear assembly
in mesh with the input shaft. The gears are of different
sizes to change gear ratios when meshing with the
two shifter gears.
SHIFTER FORK - A mechanical arm which is connected
to the shifter rod to position the shifter gear at an exact
spot axially along the shifter shaft.
THRUSTER RACE - A thrust washer in which the outer
edge is cupped to fit the outer diameter of a thrust
bearing. This fit positions the thrust race concentric
with the axle diameter. It further acts as a thrust washer.
SHIFTER GEAR, LARGE (600/2300) - This gear
transmits 1st gear, reverse gear (and 2nd gear in 4-
speed units) ratio force to the output shaft. It is beveled
on both sides.
THRUST WASHER - A flat polished surface separating
metals of different hardness. It also acts as a spacer
between shafts and the case and cover.
SHIFTER GEAR, SMALL (600/2300) - This gear
transmits 2nd and 3rd (3rd and 4th in a 4-speed unit)
gear ratio force to the output shaft. It can have two
different beveled tooth diameters or it can have a beveled
spline to engage 3rd (or 4th) gear through an additional
splined shaft.
TRANSMISSION - A system of varying sized gears
in a case, some of which can be moved along a shaft
to vary the gear ratio in a unit. The net effect is to
change speeds to the rear wheel according to the type
of work being done.
UNIT - A general term for Tecumseh/Peerless
Transmission products.
4
3
. Remove the shift housing and drain the lubricant
from unit. Observe the old lubricant to see if metal
particles are present.
GENERAL SERVICING PROCEDURES
The following service procedures should be understood
and practiced whenever service is needed on a
Tecumseh transmission or drive product.
4
. Check axle shafts carefully for smoothness. Use
crocus cloth or a Scotch-Bright™ pad to rub down
high spots and eliminate rust or paint from the shafts.
It is recommended that you take
WARNING
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
5. Check the model and specification number and
remember to have the exploded parts diagram
accessible during disassembly.
6
. Have on hand seal protectors, drivers, shop cloths,
appropriate tools and this technicians handbook
while servicing a unit.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
OIL LEAKS, SEAL AND GASKET SERVICE
Tecumseh units contain various styles and sizes of
oil seals. The function of any oil seal is to seal inward
to prevent lubricant leaks and prevent outside debris
from entering the unit. Seals can be single lipped
with the sealing edge facing inward or double lipped
sealing inside and out.
Before removing a unit (Transmission product) from
any equipment, look for and ask the customer about:
GUIDELINES TO REMEMBER
1
2
3
. Loose, worn or glazed drive belts.
. A misadjusted or badly worn clutch or belt tension.
. Loose/lost set screws and or sheared keys in drive,
driven pulleys or axle.
1
. Other than leaking seals, gaskets and “O” rings,
leakage can occur due to a cracked case or cover,
flats on shafts, porosity (rarely, if ever), and worn
bushings and shafts.
4
. Oil saturated drive belts or clutches.
. Bad operating habits, such as clutch riding or not
clutching when shifting.
5
2
3
4
. Replace ALL seals/gaskets if disturbed. The small
cost of installing new seals is small in comparison
to a dissatisfied customer and the cost of rework.
6
. Oil leaks.
7
. If possible operate the equipment to help isolate
the problem.
. Some seals have a "Redicoat" sealant applied,
while others may need a thin coat of RTV silicone
to the outer shell upon installation.
8. Review Service Bulletin 304.
Removal of the unit from the equipment:
1
. Raise the equipment so the transmission or transaxle
is accessible. Use wood blocks to prevent
equipment from shifting. Do not use bricks, cement
or cinder blocks.
. The surface over which the seal makes contact
must be free of all cuts, scratches, high spots and
rust. The shafts should be smooth, shiny and a
thin film of light oil applied. Seal protectors must
be used to clear keyways, splines, or other machined
sharp edges on the shafts.
2
. Visually inspect the Tecumseh unit for oil leaks, a
cracked housing, binding or rubbing of parts, or
other symptoms of malfunction.
3
. Use a jack under the unit to support it’s weight
when attachments are removed.
TORQUE VALUE TROUBLESHOOTING
GUIDELINES
4
. Remove wheels, drive belts, pulleys, chains and
other associated equipment from the unit. Be aware
of positioning of parts. Use a scribe mark, if in
doubt, to reassemble parts quickly and accurately.
. If the shifter lever will interfere with removal of the
unit in anyway, remove it before unit removal. These
can easily be bend out of shape.
ALWAYS torque all fasteners to the appropriate value
as listed in Chapter 1 page 9.
5
6
7
Over-tightening can strip the threads in the cases or
on a fastener. It also can over-compress gaskets,
and possibly cause binding in the unit.
. Remove all attached hardware holding the
Tecumseh/Transmission unit to the equipment on
the case, cover, axle supports, brake and shifter.
. Remove the unit from the equipment.
A cross-tightening sequence to half the torque then
finally to full torque value is a recommended procedure
to prevent comebacks (repair returns).
Preparing for disassembly of a unit:
Under-tightening fasteners can cause oil leakage,
loosening of attaching parts, and possible shifting of
the internal parts which may bring about a complete
failure.
1
. Visually inspect for evidence of oil seepage,
tampering, misalignment, freedom of rotating shafts,
etc.
2. Clean the unit thoroughly of any dirt, oil and debris.
5
BASIC TESTING
The absence of binding and oil leakage are the best
indications that the unit has been properly reassembled.
Though other, more elaborate tests can be done, the
following procedures are accurate and the preferred
method for a quick check of the unit.
On an "H" shift pattern drive with the shift forks in
neutral, rotate both axle ends in the same direction.
They should turn smoothly although a little effort may
be necessary. The brake shaft should rotate whenever
the axles turn together, but in neutral, the input shaft
should not turn. By moving any shifter gear into mesh,
a greater drag should be felt on the axles, and both
the input and brakeshaft should turn. For ease in turning
the various shafts, insert a tool (such as a punch or a
socket head screw key) into the keyway, however, do
not force if the shaft is binding.
Potential reasons for binding in the unit could be:
1
2
3
4
. Gaskets were left out on reassembly or installed
incorrectly.
. Oil seal retainers, differential, thrust washers, shifter
stop or oil seal retainers were installed improperly.
. The shifter assembly or spacers were installed
incorrectly.
. Foreign matter could be blocking the gear teeth
that are in mesh.
5. The input shaft was not properly seated in the case.
6. The case and cover could be mis-aligned (dowel
pins were missing).
7
. The bearing(s) do not have the lock tabs or notches
in the correct position.
For more information, consult the troubleshooting
section.
6
LUBRICATION CHART
Check the Transmissions unit model and specification number before filling with lubricant. There may be a
difference in the quantity recommended. This is dictated by the design of the vehicle and position of the
transmission unit installed.
Model
No.
Model
No.
Model
Quantity
Sealed
24 oz./710 ml Oil
30 oz./887 ml Grease
36 oz./1065 ml Grease
36 oz./1065 ml Grease
26 oz./769 ml Grease
18 oz./532 ml Grease
Quantity
No.
Quantity
3
00
700
12 oz./355 ml Grease
12 oz./355 ml Grease
†
All Models
Except *
*1408-P91
*1409-P91
*1410-P91
*3002
6
8
8
8
9
9
00
00
01
20
00
10
700H
2800
4 oz./118 ml Grease
3 oz./89 ml Grease
*3003
9
15/940 10 oz./296 ml Grease
*3028
9
9
20
30
30 oz./887 ml Grease
30 oz./887 ml Grease
48 oz./1420 ml Oil ††
*3029
*3035
1
200
305
309
313
301
302
303
304
306
307
308
310
311
312
314
315
316
317
318
320
321
322
325
328
329
319
323
326
327
1000 Series 6 oz. / 180 ml
SAE E.P. 80W90 Oil
16 oz./473 ml Oil
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
32 oz./946 ml Oil
1100
DIFFERENTIALS
All Models 3 oz./89 ml Grease
TWO SPEED AXLE
All Models 2 oz./59 ml Grease
THREE SPEED AXLE
All Models 2 oz./59 ml Grease
44 oz./1301 ml Oil
NOTICE
Grease: Bentonite Grease
Part Number 788067C
Oil: SAE E.P. 80W90 Oil
Part Number 730229B
† Refer to O.E.M. Technician’s Manual for
type of lubricant and capacity system
24 oz./710 ml Oil
†
† To be filled through shift lever opening
MST
16 oz./473 ml Oil
2300
2400
2500
2600
64 oz./1892 ml Oil
32 oz./.946 ml Oil
†
†
7
TORQUE VALUES CHART
MODELS
PART
AFFECTED
IN-LBS
FT-LBS
NM
Bolt 5/16-18 (Housing)
Nut 5/16-18 (Housing)
100 Series
100 Series
228-264
120-156
19-22
10-13
25.8 - 29.9
13.6 - 17.7
Bolt 1/4-20 (Case to Cover)
600 Series
600 Series
84-108
7-9
9.5 - 12.2
Bolt 5/16-18 (Axle Support Housing)
156-180
13-15
17.7 - 20.4
Bolt 1/4-20 (Shift Lever Housing)
Bolt 1/4-20 (Brake Disc)
600 Series
600 Series
84-108
84-108
7-9
7-9
9.5 - 12.2
9.5 - 12.2
Bolt 1/4-20 (Case to Cover)
800 & 900 Series
(
Except 820)
90-100
85-110
7.5-8.3
7.1-9.2
10.2 - 11.3
9.7 - 12.5
Bolt 1/4-20 (Brake Disc)
800, 900 & MST Series
Bolt 5/16-18 (Case to Cover)
Bolt 1/4-20 (Bearing Cap)
Bolt 1/4-20 (Differential)
820 Series
820 Series
820 Series
180-216
90-100
84-120
15-18
7.5-8.3
7-10
20.4 - 24.5
10.2 - 11.3
9.5 - 13.6
Bolt 1/4-20 (Brake Disc)
820 Series
1100 Series
2800 Series
85-110
180-216
180-216
7.1-9.2
15-18
15-18
9.7 - 12.5
20.4 - 24.5
20.4 - 24.5
Bolt 5/16 x 18
Bolt 5/16 x 18
Bolt 1/4-20 (Case to Cover)
Bolt 1/4-20 (Shift Lever Housing)
Bolt 1/4-20 (Differential)
1200 Series
1200 Series
1200 Series
96-120
84-108
84-120
8-10
7-9
10.9 - 13.6
9.5 - 12.2
9.5 - 13.6
7-10
Bolt 1/4-20 (Case to Cover)
Bolt 1/4-20 (Differential)
1300 Series
1300 Series
90-110
84-120
7.5-9.2
7-10
10.2 - 12.5
9.5 - 13.6
Bolt 1/4-20 (Case to Cover)
Bolt 1/4-20 (Shift Lever Housing)
Bolt 1/4-20 (Differential)
1400 Series
1400 Series
1400 Series
96-120
84-108
84-120
8-10
7-9
10.9 - 13.6
9.5 - 12.2
9.5 - 13.6
7-10
Bolt 1/4-20 (Case to Cover)
Bolt 1/4-20 (Shift Lever Housing)
Bolt 5/16-18 (Axle Support Housing)
Bolt 1/4-20 (Differential)
2300 Series
2300 Series
2300 Series
2300 Series
96-120
96-120
180-216
84-120
8-10
8-10
15-18
7-10
10.9 - 13.6
10.9 - 13.6
20.4 - 24.5
9.5 - 13.6
Bolt 3/8-16 (Axle Support Housing)
2300 Series
240-312
20-26
27.2 - 35.4
Bolt 1/4-20 (Case to Cover)
Bolt 1/4-20 (Axle Support Housing)
Bolt 1/4-20 (Differential)
2400 Series
2400 Series
2400 Series
96-120
96-120
84-120
8-10
8-10
7-10
10.9 - 13.6
10.9 - 13.6
9.5 - 13.6
Bolt 5-16/18 (Case to Cover)
Bolt 3/8-16 (Differential)
2500 Series
180-216
420-480
720-780
15-18
35-40
60-65
20.4 - 24.5
47.6 - 54.4
81.6 - 88.4
2500 & 2600 Series
2500 & 2600 Series
Bolt 1/2-13 (Axle Support Housing)
Screws No. 10-24 (Cover)
Bolts 1/4-20 (Retainer Cap)
R.A.D.
R.A.D.
20-24
1.6-2
2.2 - 2.7
90-110
7.5-9.2
10.2 - 12.5
NOTE: On all units containing two jam nuts, secure brake lever, hold the bottom nut and torque the
top nut to 100 in. - lbs. (11.3 Nm).
Differential Bolts
7 ft. - lbs. (9.5 Nm)
“
“
T” Drive Bolt
T” Drive Cover Screw
8-11 ft. - lbs. (10.9 - 15.0 Nm)
20-24 in. - lbs. (2.24 - 3.7 Nm)
8
RIGHT ANGLE DRIVES
1100 SERIES
1
00 SERIES
A or B
3
00 SERIES
1
200 SERIES
A
A
A or B
7
00 SERIES
A or B
A
6
00 SERIES
A
A or B
A
8
8
10 SERIES
01 SERIES
2
600 SERIES
2
800 SERIES
A
A
910 SERIES
9
9
9
00 SERIES
20 SERIES
30 SERIES
A
1
300 SERIES
A
2
400 SERIES
A
9
15 SERIES
8
20 SERIES
A
2
300 SERIES
2
500 SERIES
A or B
A
A or B
MST
SPECIFICATION NUMBER
REQUIRED FOR WARRANTY
MOD 506
MODEL NUMBER REQUIRED
FOR WARRANTY
PEERLESS
1
275 1374
VARIOUS STYLES OF
IDENTIFICATION
USED
Individual Serial Number
Manufactured on the 275th Day
Manufactured in 1991
D.O.M. (DATE OF MANUFACTURE)
ORIGINAL SERIAL NUMBER
MODEL NUMBER REQUIRED SPECIFICATION NUMBER
FOR WARRANTY
REQUIRED FOR WARRANTY
SPECIFICATION NUMBER
REQUIRED FOR WARRANTY
MODEL NUMBER REQUIRED
FOR WARRANTY
D.O.M. (DATE OF MANUFACTURE)
ORIGINAL SERIAL NUMBER
D.O.M. (DATE OF MANUFACTURE)
ORIGINAL SERIAL NUMBER
Early Models were not identified with a model number on the unit.
THE MODEL NUMBER WILL BE FOUND ON: A. Metal tag or decal attached to unit as illustrated.
B. Stamped on unit as illustrated.
Identification Number Locations
9
TROUBLE SHOOTING TABLE
THE FIRST RULE IN TRANSAXLE TROUBLE SHOOTING IS TO ISOLATE THE PROBLEM TO THE TRANSAXLE.
THE TECHNICIAN MUST CHECK FOR PROPER ADJUSTMENT OF THE BELTS, BRAKE, CLUTCH, SHIFTER
AND LINKAGES. THE PULLEYS NEED TO BE CHECKED FOR SHEARED RETAINERS AND PROPER BELT
DISENGAGEMENT. IF THE PROBLEM IS RELATED TO SHIFTING DIFFICULTIES, REMOVE THE DRIVE
BELT AND RECHECK THE SHIFTING TO ASSURE THE PROBLEM IS NOT WITH THE ASSOCIATED
EQUIPMENT.
With the engine off, shift through the gear sequence. Only light resistance should be felt. If the unit
shifts hard the problem is in the transaxle. Otherwise, check the following areas: the clutch adjustment,
brake adjustment, belt release and the belt guide positioning.
All current gear drive units are in-line shift and use shift keys to engage the desired gear to lock and then rotate
with the shaft. This type of unit requires the transaxle or transmission to be in a no load condition (the clutch
engaged) when gear selection occurs. Depressing the clutch pedal and therefore engaging the clutch, allows
the unit to have the input and brake forces removed from the gears and shift keys, which allows the unit to shift
freely and easily. Improper shifting (shifting while on an incline, shifting while towing any type of load, or shifting
without clutch engagement) forces the shift keys to engage into a gear that is in a loaded condition. Improper
shifting leads to premature wear and failure of the shift keys and drive gears and is considered abuse. Tecumseh's
limited warranty covers only transaxle or transmission failures that are the result of a defect in the material or
workmanship of the unit, not failures caused by normal wear or abuse by the operator.
Some Original Equipment Manufacturers (OEM)'s use Tecumseh transaxles and transmissions in lawn tractors
that do not use a foot operated clutch. These lawn tractors combine the clutch release mechanism with the
hand operated gear shift lever. When the gear shift lever is moved through the shift gate from the gear engagement
position toward the neutral position, the attached clutch linkage moves the idler pulley to release all input drive
belt tension from the transaxle input pulley. With the drive belt tension released (clutch engaged), the transaxle
is able to shift while on an incline or while towing any type of load. Remember, the Tecumseh Peerless limited
warranty covers defects in the material or workmanship. It does not cover worn shift keys or gears caused by
clutch/belt linkages not adjusted correctly.
Isolate Unit from Transaxle
Use the following procedure to determine if a hard shifting condition is caused by the shifter/clutch linkage or
an internal problem in the unit.
1.
On level ground, start the engine and with engine running proceed to shift through the gears with the clutch
pedal depressed (engaged).
2
.
.
If shifting is difficult, try shifting the transaxle with the engine shut off.
3
If the transaxle shifts freely through each gear with the engine shut off, the cause of the shifting problem is
external to the unit. DO NOT REMOVE THE TRANSAXLE.
4.
5.
6.
If shifting the unit with the engine shut off is difficult then disconnect the linkage from the shifter rod and
shift through the gears with an open end wrench and compare the shift effort.
Check the clutch, shifter, and brake linkage for the proper adjustment by using the guidelines provided by
the owner's manual or the Technician's Handbook for that specific equipment.
Hard shifting with the engine shut off can be caused by:
a. bent or binding shift lever or linkage.
b. shift linkage out of adjustment.
c. corrosion in the transaxle or transmission.
d. damaged shift keys, gears or shifter brake shaft.
e. missing or misadjusted belt guides (see the (OEM's specs).
NOTE
DO NOT REMOVE TRANSAXLE UNTIL YOU HAVE CHECKED ITEMS 6A AND 6B.
If the problem is internal, remove the transaxle from the equipment, disassemble and determine the cause.
10
TROUBLESHOOTING TABLE
PROBLEM
REMEDY
UNIT CANNOT BE SHIFTED (OR DIFFICULT TO SHIFT)
Gears installed incorrectly
Review positioning of gearing.
Forks and Rod assembly installed incorrectly
Remove assembly, recheck and correctly position parts.
Axle Housing installed incorrectly or not
tightened correctly/ Axles cannot be turned
Seal retainers are not properly sealed. Tighten axle housing
bolts.
(
in the same direction) while unit is in Neutral
Shifting lever improperly positioned
Determine if finger of shifting lever is correct for the unit
and is correctly installed. Make sure shift lever housing
has the required gasket.
Shifting keys broken or damaged
Shifting washers in backwards
Replace keys and check unit for additional damage.
Chamfered side on the inside diameter of the washer
must face the tips of the keys.
Shifter/Brake shaft keyways damaged
Shift lever housing misaligned to case
Remove nicks and burrs from keyway.
Check if alignment marks on unit are correctly positioned.
Also, determine if bend on shaft is in correct position.
Equipment clutch not engaging
Shifter stop assembled backwards
Adjust clutch according to the operator manual of the
equipment.
Determine that the notch in the shifter STOP aligns with
shifter forks in the NEUTRAL position.
Shift gear chamfer is positioned on the
wrong side
Check that bevels on shifter gears are correct (fork flanges
should be toward each other). On three-gear cluster
models, the small gear and medium gear chamfers go
down toward the larger gear. In-line models have the
chamfer side of the gear facing toward the brake disc.
Improper fit of case to cover
Recheck positioning of thrust washers. A misplacement
or omission of a washer can cause binding. Be sure
that all tabs are down in the corresponding notches located
in the case.
Dowel pins not installed
Check the exploded view for a correct assembly of parts.
Check the exploded view for a correct assembly of parts.
Gears improperly installed
Input shaft not properly installed
Input shaft spline must fit into the gear squarely and be
tapped completely into the case.
Differential installed improperly
Re-check the positioning of the bolts in the differential.
It must be opposite the output shaft gear (except 2400).
In-line shift models need to have the differential gears
centered so they will spin freely in the case with the
cover removed.
Seal retainers improperly positioned
Check that seals are correctly installed.
11
TROUBLESHOOTING TABLE (Continued)
PROBLEM
REMEDY
UNIT JUMPS OUT OF GEAR
Gear teeth are worn beyond tolerances
Spring in shifter fork weak or broken
Replace worn gears.
Replace spring.
Attaching screws for shift lever and housing
assembly not properly torqued
Torque screws to 10 ft. lbs. (13.6 Nm).
Shifter/Brake shaft improperly assembled
Keys weak or worn, shift gears damaged
Shift lever bent and hitting unit frame
Shift rod grooves worn
Reassemble properly per exploded view
Replace keys/Shift gears.
Replace shift lever.
Replace shift rods.
Shift rod of improper length or grooving installed
Check rod length. Replace with correct part.
Reposition gears.
Constant mesh gears improperly installed on
counter shaft
AXLES CANNOT BE TURNED (IN THE SAME DIRECTION) WITH UNIT IN NEUTRAL
Axle housing not installed (or not tightened)
Seal retainers are not properly seated. Tighten axle housing
bolts.
Burrs on gearing
Remove gear and debur with a sharpening stone.
Broken shifter stop allowing unit to be shifted into Replace snap rings on shift rod out of groove.
two speeds at the same time
Thrust washers in wrong position
Recheck thrust washer and if wrong, reposition.
Use the proper bearing tool to seat the bearing.
Bearings not pressed in deep enough
UNIT DOES NOT DRIVE
Differential bevel gears broken
Replace.
Replace.
Three gear cluster countershaft key sheared in
Model 600
Stripped teeth on gears
Keys sheared in drive pulleys
Broken input gear
Replace.
Replace.
Replace.
Shift keys broken
Replace keys/check keyways and shift gears.
Replace chain.
Reverse chain broken (reverse only unless chain
becomes wedged)
UNIT IS NOISY
Gearing is overly noisy chatter, etc.
Metallic pieces or other foreign objects in unit
Worn gears
Check oil/grease level.
Remove bits of broken metal, loose washers, etc.
Remove and replace with new gears.
Worn bearings, mainly input shaft ball bearing
Replace the bearing in question/check the belt tension.
12
CHAPTER 2. 300 SERIES
GENERAL INFORMATION
Basic Troubleshooting
The 301 series is a single speed transmission
manufactured in various styles to meet customer
application needs. The unit uses synthetic lubrication
and is completely sealed for life and therefore not
internally serviceable.
Should a drive problem exist, check the following:
Cable adjustment
2. Belt tension and mechanism
Drive lever operation
4. Check for worn or glazed belt or damaged pulley
1
.
3
.
Only the external parts listed below in the illustration
are available from your normal source of supply.
5
.
Should the unit still not operate correctly
replacement will be required.
Q
R
S
T
Externally Serviceable Parts
U
SERVICEABLE PARTS
1
2
3
4
5
. Retaining Ring
. Drive Pulley
. Tension Spring
. Retaining Ring or Push Nut
. Drive Arm
ID LOCATION
13
CHAPTER 3. 600 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
WARNING
INPUT SHAFT
CASE
COVER
LE
When shifting gears verify the
RIGHT
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
NG
CENTER PLATE
DO NOT shift on a hill or when
DISC BRAKE
WARNING
SHIFT LEVER HOUSING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
IDENTIFICATION PLATE
A
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
GENERAL INFORMATION
BRAKE SHAFT
CASE
There are two types of 600 Series transaxles. One is
the 600 standard series and the other is the 601-001,
2. After removing axle housings bench or clamp the
transaxle in a soft jaw vise. Position the transaxle
so that the socket head cap screws are facing
up.
0
02, 003, etc. slow speed series transaxle. This first
section will deal with the standard 600 series. Please
refer to the next section for information on 601 slow
speed transaxle.
The 600 Series transaxle has an aluminum case and
cover. The input shaft is on the top of the case to
receive vertical shaft power from the engine. Some
PIN
6
00 series transaxles are equipped with an optional
disc brake. Due to the many variations of equipment
braking systems, adjustments and repair to these
components and linkages are not considered warranty.
USING
TRANSAXLE DISASSEMBLY
NEUTRAL
POSITION
3
.
Remove the socket head cap screws holding the
case and cover together. Drive out the dowel pins
used for aligning the case and cover.
1
.
Clean the outside surface of the transaxle in an
area away from where service will take place.
Position the shift lever in the neutral position to
ease disassembly of the transaxle. Remove the
three screws holding the shift lever. Remove all
keys from key ways, and remove all burrs and
dirt from the shafts.
On hardened shafts, use a stone or crocus cloth
to remove any burrs and oxidation. All seals should
be replaced whenever a shaft is pulled through a
seal. Always use a new gasket whenever the
gasket surfaces have been separated.
14
SHIFTER
ASSEMBLY
SEAL PROTECTOR
COVER
SHIFTER GEARS
SHAFT
REVERSE IDLER
SHIFTER RODS
DIFFERENTIAL
ASSEMBLY
CENTER
PLATE
ASSY.
THREE GEAR
CLUSTER
7
.
Remove the complete shifter assembly by grasping
the shifting gears, shaft and both shifter rods as
a complete unit.
INPUT
SHAFT
NOTE
4
.
Use a seal protector on the axle shaft and lift off
the transaxle cover assembly. Because this seal
is the single lip style, it may be reused if care is
taken to see that it isn't cut or scratched.
Examine the assembly carefully; if no service is
required, keep the assembly together as a unit. If service
is necessary refer to Chapter 21 on shifting assemblies.
DIFFERENTIAL
ASSEMBLY
SCREW
FASTENERS
BEVELED EDGE
INPUT
SHAFT
5
.
To remove the differential assembly, it may be
necessary to replace two or three screws that
hold the center plate assembly down. Pull
assembly straight up. If tight, tap on lower axle
with a soft mallet. CAUTION: DO NOT USE
STEEL HAMMER. Refer to the chapter on
differential assembly service. Remove the gear
on top of the shifter shaft.
8. Remove the reverse idler shaft, spacer and gear.
9
.
Remove the cluster gear sub assembly and thrust
washer.
CENTER PLATE ASSEMBLY
BEVELED
EDGE
SHIFTER
ASSY.
THREE GEAR
CLUSTER
6
.
After removing the center plate assembly screws,
remove center plate and discard the gasket.
15
BEVEL
LONGER KEYWAY
INPUT SHAFT
SEAL
SHORT KEYWAY
DIFFERENTIAL
ASSEMBLY
SNAP RING
SMALL GEAR
THRUST WASHER
BEARING
BEVEL
LARGE
GEAR
MEDIUM
GEAR
1
2. Remove the input shaft oil seal to allow access
to the snap ring. Remove snap ring and input shaft
will slide out. A removed seal must be replaced
by a new seal.
SLEEVE
LARGE GEAR
OLD STYLE
LONG
MEDIUM
SMALL SPACER GEAR
GEAR
NOTE
One model (612) has a sealed ball bearing instead of
an oil seal. To remove this unit, remove snap ring
inside the case and drive out. On model 612-A, remove
the oil seal in the normal manner.
SLEEVE
SHORT
BEVELED EDGE
SNAP RING RETAINER
1
0. Cluster Gear Sub-Assembly
SHIFTER
STOP
a. The cluster gear can be disassembled. All worn
gears are replaceable if damaged or worn. It's
preferred to use a press to drive the shaft out
squarely.
SHIFTER
RODS
b. The small and medium gears' bevel faces down.
There is no beveled edge on the large gear.
The shorter spacer fits between the medium
and the large gear.
SHIFTER FORKS
BRAKE SHAFT
(IN NEUTRAL POSITION)
c. Key edge ends must align with shaft ends.
SHIFTING ASSEMBLY
THRUST BEARING
The shifting assembly is usually removed from and
installed into the transaxle as a unit. The assembly
is removed and replaced by grasping the shifting rods
firmly. This will cause the binding necessary to hold
the assembly together. Before removal or installation
of the shifting assembly, the notches in the shifter
forks should be aligned with those on the shifter stop.
IDLER GEAR
THRUST
WASHERS
11. Remove the idler gear, thrust washers and thrust
bearing.
16
4
.
Insert the shifter assembly. Check that the shifter
rods are seated properly.
SHIFTER
STOP
SHIFTER
RODS
BRAKE SHAFT
This alignment indicates the shifting assembly is in a
neutral position. The shifter stop must be positioned
so the notch aligns with the notches in the shifter forks.
For service of the shifting assembly, refer to Chapter
BEVELED EDGE
5
.
Install the reverse idler. Make sure the beveled
edge is up. Place the spacer on top of the gear.
9
.
Transaxle Assembly
CENTER PLATE ASSEMBLY
1
2
. Install new seal, thrust washers, and bearing on
input shaft. Note sequence, and install into case,
using a seal protector.
SHIFTER ASSY.
THREE GEAR
CLUSTER
. Set case assembly open side up. Insert the idler
gear assembly, thrust washers and bearing. Note
sequence of washer and bearings from case; thick
washer, thrust bearing thin washer, idler gear.
6
.
Install the dowel pins to ease the cover installation.
Then place a new gasket on the case and install
the center plate. Position the differential assembly
with the longer axle in the down position and be
sure the gear on the shifter shaft is installed.
GEAR
THRUS
WASHE
SEAL PROTECTOR
COVER
CAUTION Make sure the bearing and thrust
washers remain in place while assembling the idler
gear, shifter and brake shaft.
DIFFERENTIAL ASSEMBLY
SHIFTER
SHIFTER GEARS
ASSEMBLY
CENTER PLATE
ASSY.
SCREW
FASTENERS
SHAFT
REVERSE IDLER
SHIFTER RODS
7
8
.
.
Install the cover assembly and torque the cap
screws to 7-9 ft. lbs. / 84-108 in. lbs. (9.5-12.2
Nm).
THREE GEAR
CLUSTER
If the unit needs bearings or bushings installed,
consult Chapter 22 for proper procedures.
3
. Insert the washer and then the three gear cluster
assembly. Make sure the bevels on the two shifting
gears are facing down.
17
9
.
Install the axle supports and fill with 24 oz. (710
ml) of S.A.E. 80W90 part number 730229B gear
lube. Fill through the shifter housing.
NEUTRAL
POSITION
1
0. Inspection Note: For a neutral position, shift notches
in forks and notch in stop must be aligned and
centrally located.
APPLY LUBRIPLATE
JAM NUTS
11. The brake lever type is determined by the original
equipment manufacturer's selection of this option.
Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flat washer, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. To secure the brake lever, hold
the bottom nut and torque top nut to 100 in. lbs.
(
10.2-11.3 Nm).
The brake and linkages may vary.
Follow recommended guidelines
in equipment manufacturer's
WARNING
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
18
601 SLOW SPEED TRANSAXLE
GENERAL INFORMATION
The 601 slow speed series uses the same case and
cover as the 600 series so the appearance is the same.
The following differences are as listed in three steps.
INPUT SHAFT
SEAL
SNAP RING
IDLER GEAR
THRUST WASHER
BEARING
THRUST WASHER
2
3
. The input shaft only has one thrust washer instead
of a thrust bearing and two thrust washers.
THRUST
WASHER
. The 601 also has a different input shaft and bevel
gear than the 600 transaxle.
1
. Under the idler gear is one washer instead of a
thrust bearing and two thrust washers. The 601
idler gear is different than the standard 600 Series.
6
00 SERIES BEARING TOOLS
PART LOCATION
TOOL REMOVE & REPLACE
BEARING SIZER
Brake Shaft
Axle
670210
670204
*670207A
670205
(27 needles)
0
*
Input Shaft
Center Plate
Brake
Shaft
670213(3 need
Differential
Cluster Gear
Idler Gear
Axle Housing
Reverse Idler
670204
670204
670210
670204
*
Bearing must be flush with top of case. Secure with Loctite.
19
600 SERIES TRANSAXLES
LUBRICATION
Oil Bath
4 oz. (710 ml) S.A.E. E.P. 90 Oil
2
Part No. 730229B
To be filled through shifter
lever opening.
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
20
CHAPTER 4. 700 SERIES TRANSMISSION
IN-LINE SHIFT
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
DISASSEMBLY OF TRANSMISSION
WARNING
Clean outside surface of transmission. Position shift
lever in neutral as indicated by the shift pattern.
1. If the unit has the OEM option of a neutral start
switch, remove the switch.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
2
. Remove setscrew, spring and index ball from the
transmission cover and six cap screws that fasten
the cover to the case.
DO NOT shift on a hill or when
WARNING
3. Remove cover. Remove shifter assembly (includes
shafts, pins and fan from transmission by lifting
shaft out of case.
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
SPRING
Use approved safety procedures
SETSCREW
COVER
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
INDEX BALL
GENERAL INFORMATION
CAP
SCREWS
The 700 Series in-line shift transmission is available
in 2, 3, 4 or 5 speeds forward depending on equipment
manufacturer’s specifications.
CASE
The two speed version is not covered here but can be
disassembled and reassembled using the same
information for the 700 described in this section.
4
. Remove gear and shaft assemblies from the case
lifting the two shaft assemblies together taking care
not to separate the drive chain and sprocket
relationship. Take note that the "fat" side of the
sprockets must face the tips of the keys.
NEUTRAL START
PROVISION
I.D. TAG
SHIFTER ASSEMBLY
SHIFTER FAN
SHIFTER ROD
DISC BRAKE
OUTPUT
SPROCKET
SHIFT PATTERN
OF ROTO-SHIFT
SHIFTER ROD
Optional features include right or left hand output and
a disk brake, for either in-line or “H” pattern unit.
NOTE
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
SHIFTER PINS
NEUTRAL
START
SWITCH
OUTPUT
SPROCKET
DISC BRAKE
21
5
. Remove the one-piece bevel spur combination gear
and the remaining splined spur gears from the
countershaft.
INSPECTION AND REPAIR
Remove grease with rags and cleaning solvent and
replace worn or damaged parts.
6
. Remove from the shifter/brakeshaft the output
sprocket, brake disc, all bushings, shifter spur
gears, sprocket, collar, keys and chamfered
washers.Note the inside chamfer on the shift
washers face the tips of the keys to compress
them and provide ease in shifting.
ASSEMBLY OF THE 700 SERIES IN-LINE
TRANSMISSION
1
. Install and secure the input shaft and bevel gear in
the case. Review paragraphs 7 & 8 and reverse
the order.
Use approved safety procedures
CAUTION
with equipment when handling
shifter/brakeshaft parts. These parts have
extremely sharp edges. Inadequate safety
precautions could result in equipment damage
and serious injury.
NOTE
All Needle bearings are lubricated with E.P. Grease.
DO NOT USE BENTONITE GREASE on needle
bearings. For maximum gear train life use Bentonite
grease only on shafts and gears, Tecumseh part
number 788067C.
COUNTERSHAFT
"FAT SIDE" MUST
FACE THE KEY TIPS
SPUR GEARS
BUSHING
BEVEL
SPUR
GEAR
CHAMFERED SHIFT WASHERS. Many older models
have a thrust washer with a 45 chamfer on the inside
o
REMOVE
BEARING AND
SPROCKET
diameter. The latest style washer has a curved or
rounded side. The purpose of the washers is to
compress the shift keys as they slide into a gear.
Therefore, the chamfered or rounded side of these
washers must face the shoulder of the shaft or towards
the tips of the shift keys. The washers are
interchangeable.
SHIFT GEARS. One side of the gear is flat and the
other side is chamfered or recessed. The flat side of
the gear is placed onto the shaft towards the shoulder
of the shaft or towards the shift keys.
THRUST WASHER
THICKEST THRUST
WASHER
SHOULDER
COLLAR
CHAIN
7. Remove the snap ring from the input shaft; remove
bevel gear and pull shaft through case.
COLLAR
SHOULDER
KEY
8
. Input shaft needle bearings should be installed flush
to .005" (.127 mm) below bearing bore surfaces
from inside and outside the case.
BEVEL GEAR
SNAP RING
KEY
OUTPUT AND
BRAKE SHAFT
THRUST WASHER
NEEDLE
BEARINGS
"O" RING
THRUST
WASHER
SNAP RING
INPUT
SHAFT
22
SHOULDER
BEVEL SPUR GEAR
COUNTERSHAFT
EARLY
STYLE
NEW
STYLE
THRUST
WASHER
(
SEPARATES
GEAR FROM
BEARING)
CUT OUT
SIDE OF
GEAR MUST
SPUR GEARS
FLAT SIDE OF
GEAR MUST
FACE
FACE
SHOULDER
ON SHAFT
OUTBOARD
END OF
SHAFT
5
6
. Install the chain over the two shafts making sure
that the collars of both sprockets face inward toward
the tips of the keys.
2
. Starting from the output sprocket end on the shifter/
brake shaft, install a chamfered washer with the
chamfer facing the shoulder on the shaft. With the
output sprocket end down, place the shaft vertically
in a vice with protective jaws and slide the collar
and keys downward toward the shoulder and through
the chamfered washer. Remember the "fat" side of
the shift collar MUST face the key tips. Use work
gloves as the keyways on the shifter/brake shaft
are extremely sharp.
. Install the appropriate protection washers on
sprocket ends and bronze oil light bushings
HUB MUST
FACE BEVEL
COUNTERSHAFT
SPUR GEARS
BEVEL
SPUR GEAR
SPUR
GEAR
BUSHING
REMOVE
BEARING
AND
SPROCKET
ANGLE
SHAFT
TOGETHER
HERE
SHIFT SPUR GEARS
CHAIN SPROCKET
BRAKE
COLLAR
KEY
WASHER
THRUST
WASHER
THICKEST
THRUST
WASHER
SHOULDER
COLLAR
CHAIN
7
. Install shifter assembly (shaft, pins and fan) 12
oz. (355 ml) of Bentonite grease around the gearing,
and reinstall the cover to the case. Torque cap
screws 90-110 in. lbs. (10.2 - 12.5 Nm).
BUSHING
OUTPUT
SPROCKET
BUSHING
OUTPUT AND
BRAKE SHAFT
3
. Install the largest gear (first gear) with the chamfered
end facing away from the key tips so that the flat
side of the gear contacts the flat side of the chamfered
washer. Remember the order as chamfer to chamfer
and flat to flat when assembling the gears on the
shifter brake/shaft. Install another chamfered washer
noting that the chamfered side makes contact with
the chamfered side of first gear. Install second
gear and all remaining gears and washers the same
way. The number of gears and/or spacers will be
determined by the number of speeds requested by
the OEM.
SHIFTER ASSEMBLY
SHIFTER FAN
SHIFTER ROD
SHIFTER PINS
4
. Install the splined bevel spur gear first (with the
bevel facing away from the shifter rod) and remaining
splined spur gears starting with the smallest to
the largest on the counter shaft as shown.
23
8
. For in-line transmissions, install the detent ball,
spring and setscrew, in that order, into the cover.
Slowly tighten the screw to flush, then one full
turn below flush. The deeper you turn in the set
screw the more tension will be on the shifter fan
which will make the gear positions feel more
deliberate to the operator.
APPLY LUBRIPLATE
BRAKE
BRACKET
9
1
. Check for binding by turning the input shaft. Install
transmission on equipment. Install brake and linkage,
and adjust to disengage when clutch is engaged.
Consult equipment Owner’s Manual.
0. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install the brake assembly.
The brake and linkages may vary.
Follow recommended guidelines
in equipment manufacturer's
WARNING
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
24
700 SERIES TRANSMISSION
LUBRICATION
Permanent Lubrication
2 oz. (355 ml) Bentonite grease
1
Part No. 788067C
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
25
700H SERIES TRANMISSIONS
It is recommended that you take
special notice of all items
SETSCREW
WARNING
NEUTRAL START
SWITCH
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
DISC BRAKE
If installed, remove the neutral start switch. This can
be an option to the OEM.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
NOTE
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
DISASSEMBLY OF THE TRANSMISSION
1
. Clean the outside of the transmission and position
the shift lever in the neutral position as indicated
by the shift pattern.
2
3
4
. Remove the shift lever by removing the four hex
screws on the shift lever cover.
CAP SCREWS (6)
. With a 3/32 inch Allen wrench, remove the set
screw, spring and detent ball.
. Remove the six cap screws that fasten the cover
to the case; then remove the cover.
SHIFT PATTERN
DISC BRAKE
HUB MUST FACE
BEVEL SPUR GEAR
COUNTERSHAFT
SPUR GEARS
BEVEL SPUR GEAR
BUSHING
SHIFTER ROD
REMOVE
BEARING
AND
The "H' pattern transmission described here is a 4-
speed forward, 1 reverse unit.
ANGLE
SHAFT
TOGETHER
HERE
SPROCKET
TORQUE SCREWS
70-90 IN. LBS
TABS IN
SLOTS
(7.93-10.2 Nm)
THICKEST THRUST
WASHER
THRUST
WASHER
SHOULDER
COLLAR
CHAIN
SHIFTER
PLATES (2)
5
. Remove the gear shaft assemblies from the case
half of the transmission by lifting the two shafts
out of the bearing supports taking care not to disturb
the drive chain relationship of the sprockets.
PLATE
6. Angle the chain and sprocket ends of shaft toward
each other, removing the bearing and sprocket from
the countershaft. Note the collar on the sprocket
faces the bevel spur gear. Remove the chain.
The 700 "H" pattern transmission gear arrangement is
similar to the in-line transmission except for the shift
gate and an additional collar and spacer on the shifter/
brake shaft. The countershaft also has an additional
spacer.
BEVEL SPUR GEAR
SPACER
Disassembly of the 700 series “H” shift pattern
includes a spacer.
26
OUTPUT
SPROCKET
SHOULDER
0
45 CHAMFER
BRAKE
DISC
CHAIN SPROCKET
KEY
COLLAR
THRUST WASHER
SEPARATES GEAR
FROM BEARING)
BUSHING
(
OUTPUT AND
BRAKE SHAFT
BUSHING
SNAP
RING
CUT OUT
SIDE OF GEAR
MUST FACE
OUTBOARD
END OF
FLAT SIDE
OF GEAR
MUST FACE
SHOULDER
ON SHAFT
Disassembly of the 700 series "H" shift pattern includes
a second collar and a spacer.
SNAP RING
BEVEL GEAR
SHAFT
THRUST WASHER
NOTE
The thrust washer on the brake disc end of the shifter/
brake shaft does not have a chamfer on the inside
diameter and must be positioned as shown above. It
is thicker than the other thrust washers separating
the gear works from the bearings.
INSTALL BEARINGS
FLUSH TO .005"
(.127mm) BELOW
CASE SURFACE
"
O" RING
NEEDLE
BEARINGS
CHAIN SPROCKET
BRAKE
DISC
SNAP RING
OUTPUT
SPROCKET
COLLAR
THRUST WASHER
KEY
INPUT SHAFT
Input shaft removal is the same for both the 700 series
in-line and “H” shift pattern transmissions.
7
. Remove the snap ring and bevel gear from the
input shaft and pull the shaft through the case.
OUTPUT AND
BRAKE SHAFT
8
. The input shaft needle bearings should be installed
flush or no more than .005" (.127 mm) below the
bearing bore surface from inside and outside the
case.
BUSHING
BUSHING
1
. The first, second and third gears have to be forced
over the keys when assembling. Remember to place
the spacer in the 4th gear position.
INSPECTION AND REPAIR
Examine all parts after removing grease with rags and
cleaning solvent to determine which parts need
replacement.
BEVEL SPUR GEAR
ASSEMBLY OF 700H SERIES TRANSMISSION
KEY
OUTPUT AND
BRAKE SHAFT
KEY
SPACER
2
. Assemble the countershaft and gears as shown
above remembering the spacer is in the 4th gear
position.
Assembly is the same as the 700 series in-line
transmission except for an additional collar and spacer.
27
COLLAR MUST FACE BEVEL
SPUR GEAR
COUNTERSHAFT
TORQUE SCREWS
70-90 IN. LBS
THRUST
WASHER
BEVEL SPUR GEAR
SPACER
TABS IN
SLOTS
REMOVE BEARING
AND SPROCKET
(7.93-10.2 Nm)
BUSHING
THRUST
WASHER
SHIFTER
PLATES (2)
ANGLE
SHAFT
TOGETHER
HERE
BUSHING
TABS
BUSHING TABS
PLATE
THRUST
WASHER
THRUST WASHER
SHOULDER
SPACER
CHAIN
6
7
. For in-line transmissions, install the detent ball,
spring, and setscrew, in that order, into the cover
and slowly tighten the screw up to two turns below
flush. Depending on personal preference. The
deeper you turn in the set screw the more tension
will be on the shifter fan which will make the gear
positions feel more deliberate to the operator.
3
. With the collar on the countershaft sprocket facing
the bevel spur gear, install sprocket onto the serration
and install chain. Install all four (4) thrust washers.
SPACER
. Check for binding by turning the input shaft. Install
the transmission on the equipment. Install the brake
and linkage and adjust the clutch according to the
equipment Owner’s Manual.
NOTCHES
NOTCHES
APPLY LUBRIPLATE
SPACER
BRAKE
BRACKET
4
. Install the bronze bushings, disc and sprocket.
Install the shaft assemblies into the case pressing
the bushing tabs into the notches in the case.
Be sure bushings tabs are seated
in transmission case, or the cover
won't sit squarely on the case.
CAUTION
SPACER
8
. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil.
NOTCHES
NOTCHES
The brake and linkages may vary.
Follow recommended guidelines
WARNING
in equipment manufacturer's
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
SPACER
5
. Install the shifter assembly, 12 oz. (355 ml) of
Bentonite grease around the gearing, installing the
cover on the case. Torque the cover fasteners 90-
110 in. lbs. (10.2-12.5 Nm).
28
700H SERIES TRANSMISSION
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
29
CHAPTER 5. 800/801 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
WARNING
INPUT SHAFT
SET
SCREW BALL
INDEX
FAN SHAFT
ROD
When shifting gears verify the
SPRING
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
IDENTIFICATION TAG
Use approved safety procedures
IDENTIFICATION
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
The unit model number will be found on a metal tag at
either of the two locations.
DISASSEMBLY
1. Clean outside surface of the transaxle.
2
. Position shift lever in the neutral position as
indicated by the shift pattern.
GENERAL INFORMATION
NOTE
3. If installed, (O.E.M. option) remove neutral start
switch.
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty. The brake
may be either a left-hand or right-hand per the O.E.M.
option.
4. Remove the allenhead setscrew, the detent ball
and spring .
NEUTRAL
START SWITCH
(OPTIONAL)
DISC BRAKE
(LEFT OR
RIGHT HAND
OPTIONAL)
SHIFT ROD
ALLENHEAD
SCREW
NEUTRAL
START
SWITCH
BRAKE
BRACKET
SCREWS
(OPTIONAL)
SETSCREW
COVER CASE HEX
SCREWS (17)
INPUT
O.E.M. OPTION)
(
NOTE
The 800/801 series transaxle is basically a combination
of the 700 series transmission with a 600 series
transaxle differential. The position of the input shaft
varies with a particular model. Because of the option
of the input shaft and gear positioning on either side
of the bevel gear, the axle output will vary, which allows
the O.E.M. the ability to rotate and reverse mount
the transaxle. The model described in this section is
a five speed forward, single reverse. The input shaft
for this model is located to the left of the bevel gear.
Prior to removing the cover and the two gear shaft
assemblies from the case, remove the square cut
O" ring from the top of the shifter rod.
"
5
. Remove the case fasteners and push the shift
rod through the cover. The shifting assembly may
temporarily remain in the case.
6
. Remove the two brake bracket screws, and remove
the brake assembly.
30
NOTE
8. Remove the needle bearing (closed end) flat washers
2), output gear and output pinion, and 3 square cut
(
Before disassembly, observe how the “V” notches on
the flanged bushings fit into the corresponding recess
in the case.
seals from the countershaft. (2 seals in the output
pinion 1 in the needle bearing cap). The "O" rings
on the countershaft are larger than those on brake
the shaft ends. Always replace with new seals
whenever service is performed.
SHIFTER/BRAKE SHAFT
CASE HALF
SQUARE CUT
"O" RING
FLANGED
BUSHING
SHIFTER FAN
FLANGED
BUSHING
OIL SEAL
OIL SEAL
SHIFTER/BRAKE
SHAFT
SPUR
GEAR
SPROCKET
COLLAR
THRUST
WASHER
BEARING
SHIFT
WASHER
FLANGED
BEARING
BUSHING
RETAINER
COUNTER-
FLANGED
BUSHING
DIFFERENTIAL
ASSEMBLY
SHAFT
SPACER
NOTE
COUNTERSHAFT
The square cut black rubber “O” rings on the shifter
brake shaft which retain the Bentonite grease in the
case.
SQUARE CUT
"O" RING
SPROCKET
COLLAR
7
. Remove gear and shaft assemblies from case half
by lifting the two shafts out of the bearing supports
taking care not to disturb drive chain relationship
with the hubs on the sprockets.
9
. Angle the shifter/break shaft and countershaft chain
sprocket ends toward each other. Note the collar
on the sprockets face the bevel gear. Next remove
the chain.
NOTE
Remove the Bentonite grease from all parts and case
halves as they are removed.
SPUR GEARS
SPLINE FOR CHAIN
SPROCKET GEAR
FLANGED
BUSHING
SHIFTER GEARS
SHIFTER/BRAKE
SHAFT
THRUST WASHER
SPUR GEAR
FLANGED
BUSHING
COUNTERSHAFT
SPROCKET
NEEDLE
BEARING
THRUST WASHER
BEVEL GEAR
FLANGED BUSHING
(
CLOSED
SPACER
THRUST
WASHER
END) OR
BALL
BEARING
KEY
COLLAR
1
0. Remove the sprocket, bevel gear, spur gears, thrust
washer, and flanged bushing. The spur gears are
splined to the countershaft.
OUTPUT
GEAR
OUTPUT FLAT WASHER (SQUARE
PINION CUT SEAL IN EACH END
FLAT WASHER OF OUTPUT PINION)
FLANGED
BUSHING
SPUR
GEARS
31
FLANGED BUSHING
SPROCKET
SPLINE FOR
DISC BRAKE
OLD STYLE
"A"
SQUARE CUT
O" RING
"
FLANGED
BUSHING
SHIFTER/BRAKE
SHAFT
SQUARE
CUT "O"
RING
"C"
NEW STYLE
"D"
"
B"
SQUARE
CUT "O" "V" NOTCH
RING
KEY
THRUST
WASHER
(NO
HEAVY DUTY
SEALED BALL
BEARING
SHIFT
COLLAR
"V" NOTCH
THRUST
WASHER
SEAL
CHAMFER)
SHIFT
WASHER
SHIFTER GEARS
The 800 Series has used four styles of bearings on
the axles. The earliest style "A" was a smaller caged
needle bearimg. Style “B” must have the seal to the
outside of the bearing. When bearing style “C” is used,
a square cut “O” ring must be used on each side of
the bearing. Bearing style “D” is a sealed ball bearing
used in heavy duty applications. Styles “B”, “C” and
1
1. From the shifter/brake shaft remove the square
cut seals (2), flanged bushings (2), thrust washers
2) on the shaft ends, spur gear, spacer, sprocket,
(
shift collar with keys, thrust washers and the shifter
gears.
“
D” are interchangeable. All needle bearings must be
FLANGED
BUSHING
repacked with grease. Never use Bentonite grease in
ball or needle bearings; use wheel bearing grease.
SEAL
BEARING
BEARING
INPUT
NEEDLE BEARING
SHAFT
FLUSH WITH
HOUSING
RETAINING RING
WASHER
SEAL
THRUST
WASHER
SQUARE CUT
"O" RING
NEEDLE
BEARINGS
FLANGED
BUSHING
DIFFERENTIAL
.
.
135" (3.43 mm)
150” (3.82 mm)
BEVEL GEAR
12. Remove the differential from the case. Remove
the (2) seals, needle bearings or ball bearings (2).
THRUST
WASHER
RETAINING RING
1
3. To disassemble the input shaft remove the retaining
ring on the bevel gear side from the input shaft;
then remove the bevel gear and pull the shaft
through the case. The square cut “O” ring must
be replaced if removed. Tool Part No. 670251 is
used for removal and installation of needle bearings
for the input shaft. The needle bearing on the inboard
side is installed .135" - .150” (3.43 - 3.82 mm)
below flush.
32
ASSEMBLY
1
THRUST WASHERS. Arunning change has been made
to the shift washers. Many models have used the
. Apply E. P. grease between bearings and install
and secure the input shaft and bevel gear in the
cover. For maximum gear train life use only
Bentonite grease on all shafts and gears, Tecumseh
part number 788067C.
o
thrust washer with a 45 chamfer on the inside diameter.
The latest style washer has a curved or rounded side.
The purpose of both washers is to compress the shift
keys as they slide into the gears. Therefore, the
chamfered or rounded side of these washers must
face the shoulder of the shaft or towards the shift
keys. The washers are interchangeable.
COLLAR
DISC BRAKE
SPLINE
SHOULDER
KEY
SHIFTING GEARS. The two sides of the shift gears
are different. One side is flat and the other side is
recessed to accept shift washers. The flat side of
the gear is placed onto the shaft towards the shoulder
of the shaft or towards the shift keys.
KEY
SHIFTER/BRAKE SHAFT
2
. Grease the keyways and slide the shift keys and
collar onto the shifter/brakeshaft. The thick side
of the shift collar MUST face the shoulder (brake
end) on the shaft. Service replacement shifter/brake
shafts will come with four keyways on the shaft
instead of two.
NOTE
When repairing the unit use, the same number of keys
that were used originally.
SHOULDER RECESS
EARLY
STYLE
NEW
STYLE
THRUST
WASHER
(
SEPARATES
SHIFT WASHER
GEAR FROM
BEARING)
CUT OUT
SIDE OF
GEAR MUST
FLAT SIDE OF
GEAR MUST
FACE
FACE
SHOULDER
ON SHAFT
OUTBOARD
END OF
SHAFT
3
. Install the thrust washers and shifting gears onto
the shifter/brake shaft. The number of gears and/
or spacers will be determined by the number of
speeds in the transmission ordered by the O.E.M.
33
FLANGED BUSHING
SPROCKET
SPLINE FOR
DISC BRAKE
FLANGED SQUARE CUT
BUSHING
FLANGED
BUSHING
SHIFTER/BRAKE
SHAFT
"O" RING
FLANGED
BUSHING
SHIFTER/BRAKE
SHAFT
SQUARE
CUT "O"
RING
SPUR
GEAR
SPROCKET
COLLAR
THRUST
WASHER
SQUARE
CUT "O" "V" NOTCH
RING
KEY
THRUST
WASHER (NO
CHAMFER)
SHIFT
WASHER
SHIFT
COLLAR
"V" NOTCH
THRUST
WASHER
SHIFT WASHER SHIFTER GEARS
SPACER
NOTE
The large thrust washer on the shift gear end of the
shifter/brake shaft does not have a chamfer on the
inside diameter.
COUNTERSHAFT
SQUARE CUT
"O" RING
SPROCKET
COLLAR
4
. Reassemble the shifter/brake shaft by installing
the sprocket and chain, spacer, spur gears, and
thrust washers. Be sure the collar on the sprocket
faces inward toward the shift collar or toward the
brake end of the shaft. Install the appropriate thrust
washers and the bronze oil light bushings on both
ends of the shifter/brake shaft; then install the square
cut “O” ring on the brake end of the shaft. Opposite
the brake end, there is a steel spacer disk; there
is not an "O" ring on that end.
6. With the ends of the countershaft and shifter/brake
shaft angled together, install the countershaft
sprocket and chain on the countershaft.
THICKER
SQUARE
CUT "O"
FLAT
WASHER
RING
LARGE WASHER
SPUR GEARS
SPLINE FOR CHAIN
SPROCKET GEAR
OUTPUT GEAR
OUTPUT
PINION
COAT AREA
WITH GREASE
.
135" -.150"
(3.43-3.81 mm)
BOTH ENDS
COUNTERSHAFT
SPROCKET
THRUST WASHER
BEVEL GEAR
FLANGED BUSHING
NOTE
7
. For correct positioning of the needle bearings use
the removal/installation tool, Tecumseh part #
Depending on the model specification, the bevel gear
may be installed one of two ways. For description
purposes, in this section, the model used has the
bevel on the gear facing inward.
6
70252. Fill the area between the needle bearings
with axle grease before installing on the
countershaft.
5
. On the countershaft, install the bevel gear and
the spur gears starting with the smallest to largest,
(
opposite the shifter/brake shaft spur gear
arrangement). Place a thrust washer and bronze
oil light bushing on the spur gear end of the
countershaft. Note that the “V” notch on the bushing
fits into the recess “V” in the case.
34
"V" NOTCH
SQUARE CUT
SET
SCREW
FAN
SHAFT
ROD
FLANGED
BUSHING
INPUT SHAFT
INDEX
BALL
SHIFTER GEARS
SHIFTER/BRAKE
SHAFT
THRUST
WASHER
SPUR GEAR
FLANGED
BUSHING
SPRING
"O" RING
NEEDLE
BEARING
(
CLOSED
SPACER
KEY
COLLAR
THRUST
WASHER
END) OR
BALL
BEARING
OUTPUT
GEAR
IDENTIFICATION TAG
FLAT WASHER
OUTPUT (SQUARE CUT SEAL
PINION IN EACH END OF
FLANGED
BUSHING
NOTE
On reassembly, use either gasket eliminator Loctite
SPUR
GEARS
FLAT WASHER OUTPUT PINION)
5
(
15 (part number 510334) or silicone RTV Loctite 598
part number 788093).
8
. Install the flat washer to protect the turning sprocket
from the square cut seal which fits into the recessed
end of the output pinion gear. Install a square cut
seal on the other end of the output pinion and the
output gear. The large protective thrust washer keeps
these in position. There is another square cut rubber
seal that fits into the recessed end of the needle
bearing sleeve assembly (closed end). Place it on
the end of the countershaft and the two shafts are
complete and ready to install into the case.
11. Install the shifter fan detent ball, spring and setscrew
in that order, into the cover, and slowly tighten the
screw one turn below flush. If unit contained a
neutral start switch, reinstall it. Check for binding
by turning the input shaft.
APPLY LUBRIPLATE
SHIFTER/BRAKE SHAFT
CASE HALF
BRAKE
BRACKET
OIL SEAL
SHIFTER FAN
OIL SEAL
BEARING
BEARING
COUNTER- RETAINER
FLANGED
BUSHING DIFFERENTIAL FLANGED
BUSHING
12. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flat washer, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install brake assembly.
SHAFT
ASSEMBLY
9
. DIFFERENTIAL ASSEMBLY
Install the flanged bushings (2), flat washers, needle
bearings or ball bearings (2), and oil seals (2), with
seal grooves facing out.
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch is
engaged. The brake and linkages may vary. Consult
the equipment owner's manual.
For teardown and reassembly of the differential,
see Chapter 18 on differentials.
Install the differential in the case.
Follow recommended guidelines
WARNING
in equipment manufacturer's
1
0. Install the shifter assembly, and pack 30 oz.(887ml)
(
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
36 oz. [1065 ml] 801 Series) of Bentonite grease
around the bearings and gearing, then reinstall
cover on the case. Torque cap screws 90-100 inch
pounds (10.2-11.3 Nm).
35
800/801 SERIES TRANSAXLES
LUBRICATION
Permanent Lub
3
3
0 oz. (887 ml)
6 oz. (1065 ml
Bentonite grea
Part No. 78806
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
36
8
20 SERIES TRANSMISSIONS
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
3. Remove cover. Remove shifter assembly (includes
shift rod and shifter fan) from transmission by lifting
shaft out of case.
WARNING
4
. Remove bearing cap, differential, shift fan, output
shaft assembly and then both the shifter/brake shaft
and countershaft simultaneously. Take note that
the "fat" side of the sprockets must face the tips
of the keys or the brake side.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
5
. OUTPUT PINION AND SHAFT.
DO NOT shift on a hill or when
WARNING
Remove sleeved needle bearings. Remove the large
thrust washers and large output gear. The output
pinion gear is machined directly onto the output
shaft in most models. There are models in which
the output shaft is splined to accept a splined output
pinion gear and a splined output gear.
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
SHIFT FAN
BEARING CAP
OUTPUT
SHAFT
ASSEMBLY
SHIFTER/BRAKE
SHAFT ASSEMBLY
GENERAL
COUNTERSHAFT
ASSEMBLY
The 820 series is similar to the 920 series transaxle
in basic operation. It has up to 6 speeds forward and
one reverse. The 820 series is a heavy duty unit which
is suited for ground engaging attachments. The 820
features ball bearings, needle bearings and steel cut
gears throughout.
NOTE
SLEEVED NEEDLE BEARINGS
DIFFERENTIAL
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
NEEDLE
BEARING
BEARING
SLEEVE
OUTPUT GEAR
"O" RING
OPTIONAL INPUT
SHIFT ROD
LOCATION
INPUT SHAFT
INDEX BALL,
SPRING AND
SET SCREW
"
O" RING
COVER/CASE
HEX SCREWS
OUTPUT
PINION
NEEDLE
BEARING
THRUST
WASHER
BEARING
SLEEVE
THRUST
WASHER
(17)
IDENTIFICATION TAG
BRAKE BRACKET
SCREWS (BRAKE
CAN BE ON RIGHT
OR ON LEFT SIDE)
NEUTRAL START SWITCH
LOCATION (OPTIONAL)
DISASSEMBLY OF TRANSMISSION
Clean outside surface of transmission. Position shift
lever in neutral as indicated by the shift pattern.
1
. The unit may have the OEM option of a neutral
start switch, remove the switch.
2
. Remove setscrew, spring and index ball from the
transmission cover and six cap screws that fasten
the cover to the case.
37
6
. COUNTERSHAFT AND SHIFTER/BRAKE SHAFT
As these assemblies are taken apart, lay the parts
out in a systematic order. This will help to make
reassembly easier and inspection of all parts
possible. Clean each part of grease as the parts
are laid out.
REASSEMBLY
NOTE
Do not apply bentonite grease to needle bearings; use
only EP grease. For maximum gear train life use only
Bentonite grease on all shafts and gears, Tecumseh
part number 788067C.
SHIFTER/BRAKE
SHAFT ASSEMBLY
1
. Install the input shaft, and all the associated parts
in the order shown on the input shaft breakdown.
2
. Grease all four keyways, insert keys into collar
and keyways and slide onto the shifter/brake shaft.
SHIFTER/BRAKE SHAFT
COUNTERSHAFT
ASSEMBLY
SHIFT KEYS (4)
SHIFT COLLAR
7
. INPUT SHAFT
3
. It is easier to assemble this transaxle if the
countershaft and the shifter/brake shaft are
assembled at the same time. Start by placing the
reverse chain over the reverse sprockets. Make
sure the collars on the sprockets are on the same
side of the chain, facing the brake side and toward
the tips of the keys.
The input shaft can also be removed and inspected
or serviced. Remove the snap ring on the bevel
gear and pull the shaft through the cover. The seal
must be replaced if the shaft is removed.
SNAP RING
Place the neutral spacers onto the shifter/brake
shaft with the larger inner diameter sides facing
together. Position the spacer with the largest inner
diameter radius toward the shift keys and brake
end of the shifter/brake shaft. Push the shifting
keys through the reverse sprocket and the first
neutral spacer, pull the neutral spacers and the
reverse sprocket up against the shoulder of the
shifter/brake shaft.
BALL
BEARING
INPUT SHAFT
NEEDLE BEARING
LARGE
INNER
LARGER RADIUS
SPACE TOWARD
DIAMETERS
SEAL
SHIFT KEYS
FACE EACH
OTHER
THRUST WASHER (Large)
"
O" RING
NEUTRAL
SPACERS
THRUST WASHER (Small)
THRUST BEARING
THRUST WASHER
GREASE
THESE
AREAS
CUPPED THRUST
WASHER
REVERSE
CHAIN
INPUT PINION
SNAP RING
SPROCKET
COLLARS
8
. DIFFERENTIAL
Refer to Chapter 18 on differentials for service.
Should disassembly of the differential be necessary,
oz. (.59 ml) of bentonite grease should be placed
around the gears on reassembly.
2
38
4
. Insert the countershaft into the smaller reverse
sprocket. Then install the large bevel gear, with
the bevel facing away from the reverse sprocket.
Place thin thrust washer on the countershaft next
to the bevel gear.
NOTE
It is not only important that gears match up diameter-
wise, but must match up according to thickness. As
all the gears are placed back into the assembly, pack
each with bentonite grease.
COUNTERSHAFT
LARGE INPUT
BEVEL GEAR
THRUST WASHERS
BEARING
ASSEMBLY
THRUST
WASHER
NOTE
THRUST WASHERS
Depending on model, the bevel may be installed one
of two ways. For description purposes in this section,
the model used has the bevel side of the large bevel
gear facing away from the reverse sprocket; in other
models the bevel may face toward the reverse sprocket.
In either case there is a thrust washer placed on the
counter shaft after the large bevel gear. Some models
may also have the smallest spur gear machined onto
the countershaft. In this case the large bevel gear
must be placed onto the countershaft prior to inserting
shaft into the reverse sprocket. These models will
not have a thrust washer placed next to the large bevel
gear.
SLEEVE NEEDLE
BEARING "O"
RING ASSEMBLY
THRUST
BEARING
SPACER
WASHER
6
. In the model pictured above, a thrust washer, thrust
bearing, thrust washer and sleeved needle bearing
with an “O” ring are placed on the countershaft next
to the reverse sprocket. Place a spacer washer
and sleeved needle bearing with an “O” ring next
to largest spur gear. Install the sleeved needle
bearing with the step facing outward and the wider
portion of the bearing sleeve toward the cover. This
will be true for all future sleeve bearing installations.
SHIFT GEARS
SHIFT
WASHERS
NOTE
On models with the large bevel gear facing in the opposite
direction, the two thrust washers and the thrust bearing
will be placed next to the largest spur gear, and the
spacer washer will be placed next to the reverse
sprocket. See the diagram at the top of the next page.
THRUST
WASHER
THRUST
WASHER
SPUR GEARS
SHIFTING
WASHER
FLAT SIDE
CUT OUT SIDE
5
. Build the gears on the countershaft and shifter/
brake shaft alternately, meshing each gear with
it’s mating gear on the other shaft. The first gear
on the shifter/brake shaft is the largest of the shift
gears. Place this gear next to the neutral spacer
with the flat side of the gear next to the spacer.
Place a shift washer onto the shifter/brake shaft
with the rounded edge towards the shift keys.
Continue this procedure until all the gears on both
shafts have been added.
SPUR GEAR
BEARING
ASSEMBLY
BEARING ASSEMBLY
7
. Place a large thrust washer next to the last shifting
gear (this may be a step washer on some models)
then a sleeved needle bearing with an “O” ring. Place
the spur gear, small thrust washer and sleeved needle
bearing with “O” rings on the opposite end of the
shifter/brake shaft.
39
NOTE
11. Guide cover over shift rod and position onto case.
Torque cover screws 180-216 inch pounds (20.4-
Dependent on whether the brake is on the right or the
left, will determine which end uses a capped sleeved
needle bearing.
2
4.5 Nm). Replace the detent ball, spring, and
set screw. Turn set screw one (1) turn below flush.
Install the neutral start switch if applicable. Check
for binding by turning the input shaft.
8
. Place the output gear on the stepped end of the
output pinion. Place thrust washers on each end
and then the large sleeved needle bearings with
SHIFT ROD
INDEX SET SCREW
"
O" rings. The "O" rings protect the axle/wheel
bearing grease in the sleeved needle bearing from
the Bentonite grease which lubricates the spur gears.
Install the three shaft assemblies into the case.
BEARING
SLEEVE
NEEDLE
BEARING
OUTPUT GEAR
"O" RING
NEUTRAL START
SWITCH
"
O" RING
OUTPUT
PINION
NEEDLE
BEARING
THRUST
WASHER SLEEVE
BEARING
THRUST
WASHER
APPLY LUBRIPLATE
9
.
Insert differential into the case; position the caged
ball bearings on the axle ends into the recessed
areas of the case. Place the bearing cap over the
sleeved needle bearing of the countershaft and
torque the bolts 90-100 inch pounds (10.2-11.3
Nm). Install shifter fan and pack the transaxle
with remaining bentonite grease. (36 oz. / 1065
ml total)
BRAKE
BRACKET
1
0. Clean mating surfaces of the case and cover; place
a continuous thin bead of sealant all around the
seam. Use Loctite Gasket Eliminator #515,
Tecumseh Part No. 510334 or the Loctite Silicone
RTV 598, Tecumseh Part No. 788093.
BEARING CAP
SHIFTER
ASSEMBLY
12. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install brake assembly.
BALL BEARING
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch
is engaged. The brake and linkages may vary.
Consult the equipment owner's manual.
BALL BEARING
DIFFERENTIAL
Follow recommended guidelines
WARNING
in equipment manufacturer's
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
40
820 SERIES TRANSMISSION
LUBRICATION
Permanent Lubrication
6 oz. (1065 ml) of Bentonite grease
Part No. 788067B
No acceptable substitute)
3
(
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
41
CHAPTER 6. 900 SERIES TRANSAXLES
DISASSEMBLY OF TRANSAXLE
It is recommended that you take
special notice of all items
WARNING
Clean outside surface of transaxle. Position shift lever
in neutral as indicated by the shift pattern.
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
1
. The unit may have the OEM option of a neutral
start switch, remove the switch.
When shifting gears verify the
WARNING
2
. Remove Allen head setscrew, spring and detent
ball from the transmission cover and six cap screws
that fasten the cover to the case.
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
3
4
. Remove cover. Remove shifter assembly (includes
shift rod, and shifter fan from transaxle by lifting
shaft out of case.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
. Remove two brake bracket screws and remove brake
assembly.
Use approved safety procedures
WARNING
NOTE
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
Remove grease from the unit as parts are removed. It
will be difficult to keep parts from falling off the
assemblies. Note position of parts before removal.
NOTE
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
SHIFT FAN
ASSY.
5
. Remove the gear and shaft assemblies from the
case half.
NOTE
Before disassembly, observe how the bushing tabs
on the flange bushings fit into recess “V” notches of
the case. The cover will rock back and forth and not
rest tightly on the case if these bushing tabs are not
pressed down in the "V" notches.
GENERAL
The 900 series is similar to the 800 series transaxle
but has only up to 4 speed offerings forward and 1
reverse. The differential utilizes bearing blocks and
is retained by the case and cover. This unit contains
an aluminum tag at location A or B, showing the model
number.
COUNTERSHAFT
OUTPUT SHAFT
COVER CASE HEX
INPUT
SHAFT
SHIFT ROD
SCREWS
"V"
NOTCHES
A
B
ID TAG
SHIFTER/BRAKE
SHAFT
6
. To disassemble the countershaft, output pinion and
shaft assembly, simply pull apart.
42
COUNTERSHAFT
10. DIFFERENTIAL
7
. Remove the two (2) thrust washers, sprocket, bevel
gear, spur gears and flanged bushing. The sprocket,
bevel gear and spur gears are splined to the
countershaft.
Remove the top bearing block on the bull gear of
the differential. Remove the bull gear, bevel pinion
gears with center shaft, and the axles. Grasp the
axle bevel gears between your thumb and fingers;
hold together while lifting differential from case.
Remove bottom bearing block from case.
COUNTERSHAFT
BUSHING
BEARING BLOCKS
BEVEL
GEAR
AXLE
2
SNAP RINGS
WASHER
BEVEL PINIONS
RING GEAR
11. INPUT SHAFT
OUTPUT GEAR
Remove retaining ring on bevel gear end from the
input shaft, remove bevel gear and pull shaft through
case. The square cut “O” ring must be replaced, if
removed.
BUSHING
PINION GEAR
SHAFT
BUSHING
INPUT
NEEDLE BEARING
FLUSH WITH
HOUSING
SHAFT
RETAINING RING
WASHER
WASHER
WASHER
SQUARE CUT
"O" RING
NEEDLE
BEARINGS
8
9
. OUTPUT PINION AND SHAFT
Remove the large brass bushing, large washer,
large output gear, washer and bushing. The shaft
and output pinion gear come as an assembly.
.
.
135" (3.43 mm)
150" (3.81 mm)
BEVEL GEAR
THRUST
WASHER
RETAINING RING
. SHIFTER SHAFT
Remove the square cut “O” ring (1) and flanged
bushings (2), thrust washers (2) on shaft ends,
shift collar with keys, sprocket, spacer, shifter gears
and thrust washers.
Tool part no. 670251 is used for removal and
installation of needle bearings for the input shaft.
The needle bearing on inboard side is installed
.
135"-.150” (3.43-3.81 mm) below flush.
BUSHING
BUSHING
KEY
SHIFTER
GEAR
SHIFTER
COLLAR
NEUTRAL
SPACER
43
REASSEMBLY
SHIFT WASHERS
1
. Apply E.P. grease between bearings in the cover
and install the input shaft, square cut seal, thrust
washers, bevel gear and snap ring.
NOTE
Needle bearings are lubricated with E.P. grease. Do
not use bentonite on any needle bearing. For maximum
gear train life use bentonite grease on shifter/brake
shaft.
SHIFTING GEARS
CUT OUT SIDE
OFGEAR
FLAT SIDE OF
GEAR MUST
FACE SHOULDER
ONSHAFT
MUST FACE
OUTBOARD
END OF SHAFT
2
. Grease both keyways and slide keys and collar on
the shifter/brake shaft.
NOTE
5
. Place the largest of the shifting gears with the flat
side of the gear next to the neutral spacer. Then
place a shifting washer with the chamfer on the
inside diameter of the washer next to the gear. The
chamfer or rounded side must face towards the
shifting keys.
When reassembling the 900 series it is easier to
assemble the shifter/brake shaft and the countershaft
at the same time.
REVERSE SPROCKET
COLLAR
"O" RING
NOTE
"O" RING
As all the gears are placed back into the assembly,
each should be packed with bentonite grease.
LARGE
BUSHING
NEUTRAL SPACER
3
. Place the reverse chain on the reverse sprockets.
Make sure the collars on the sprockets are on the
same side of the chain, facing the brake side, and
toward the tips of the keys. Slide the keys through
the sprocket and install the neutral spacer over
the ends of the shifting keys and pull them back
until the sprocket touches the shoulder of the shaft.
WASHER
THRUST
WASHER
THRUST
WASHER
6. Next place a thrust washer on each end of the
countershaft and a bushing on the end of the shaft
with the largest spur gear.
7
. On the shifter/brake shaft place a large thrust washer
next to the smallest shifting gear, next the bronze
bushing and then an “O” ring.
NOTE
Some units will use a stepped thrust washer; place
the washer onto the shaft so that the step in the washer
is out and away from the shifting gears.
SPROCKET
4
. Insert the splined countershaft into the smaller
reverse sprocket. Then place the large beveled gear
on the countershaft with the beveled side of the
gear towards the reverse sprocket. If the 900 series
is a 1, 2, or 3 speed forward unit, place a washer
over the shaft and next to the backside of the large
bevel gear. If the unit is a speed forward there will
not be a washer on the inside diameter of the washer
next to the gear. The chamfer or rounded side must
face towards the shifting keys.
8
. The end of the shifter/brake shaft (opposite the
shifting gears) has a spline. Install the spur gear
on the spline that drives the output gear. Next install
the thrust washer, bushing and “O” ring.
44
1
1
1
3. Install shifter assembly and pack 26 oz. (769 ml)
Bentonite grease around bearings, gearing, and
top of shift fan. Then reinstall the cover on the
case. Torque cap screws 90-100 inch pounds (10.2-
WASHER
WASHER
11.3 Nm).
4. Clean the mating surfaces of the case and cover.
Place a continuous thin bead of sealant all around
the seam; use Loctite Gasket Eliminator #515,
Tecumseh part number 510334 or the Loctite
Silicone RTV 598, Tecumseh Part number 788093.
FLAT
BRONZE
BUSHING
5. Install index ball, spring, and set screw in that
order into cover, and slowly tighten the screw one
(1) turn below flush. If unit contains a neutral start
switch, reinstall it now.
9
1
. To assemble the output shaft assembly, place a
washer and then the bronze bushing with the collar
Check for binding by turning the input shaft.
(
flat down) next to the pinion. Place the output
gear over the pinion as in the diagram above.
There is a washer on the outside of the gear.
APPLY LUBRIPLATE
0. After both shafts are completed, place the flanged
bushings on each end. Notice that one is larger
than the other.
NOTE
BRAKE
BRACKET
The “V” notch on the bushing fits into the recess “V”
in case.
11. DIFFERENTIAL ASSEMBLY
When assembling this unit, first make sure all parts
are there, because the unit is put together in your
hands and placed in the case at the same time.
Axles and gears must be on the center line of the
ring gear.
When installed in the case the bearing block must
have the flange to the left hand side. The bearing
block in the cover must have the flange to the
right hand side.
1
6. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install the brake assembly.
BEARING BLOCK
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch
is engaged. The brake and linkages may vary.
Consult the equipment owner's manual.
Follow recommended guidelines
WARNING
12. Before installing the differential into the case, apply
Bentonite grease to the axle bearing areas.
in equipment manufacturer's
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
SHIFT FORK
FAN ASSY.
45
900 SERIES TRANSAXLE
LUBRICATION
Permanent Lubrication
2
6 oz. (769 ml) of Bentonite grease
Part No. 788067C
No acceptable substitute)
(
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
46
CHAPTER 7. 910 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
DISASSEMBLY OF TRANSAXLE
WARNING
Clean the outside surface of transaxle. Position shift
lever in neutral as indicated by the shift pattern.
1
. The unit may have the OEM option of a neutral
start switch; remove the switch.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
2. Some 910 Series transaxles will have a Allen head
setscrew, spring and detent ball. Remove these
and the cap screws that fasten the cover to the
case.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
3. Push the shift rod through the cover and lift off.
Then remove the shifter assembly (which includes
the shift rod, and shifter fan and lift out of case.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
We caution you against the use
WARNING
of aftermarket variations of braking
systems, adjustments and service of these
components. Removing or altering factory installed
parts my affect performance and could result in
death or serious injury.
4
. Remove the two brake bracket screws and remove
brake assembly.
•
Servicing the braking system will void your
warranty. See your Authorized Tecumseh
Servicing Dealer.
5
. Remove the grease from the unit as the parts are
removed. Prior to removal of gear shaft assemblies
from the case, the shifter fan may be removed.
Note the position of the parts before removal. Some
parts may come off the shafts upon removal.
NOTE
Bentonite grease may stain clothing. Care should be
used when handling.
6
. Remove the top bearing block on the bull gear of
the differential. Remove the bull gear, bevel pinion
gears with center shaft and the axles.
GENERAL
SHIFTER/BRAKE SHAFT
OUTPUT SHAFT
The 910 series is available with 1 speed forward and 1
reverse.
INPUT SHAFT
COVER CASE
HEX SCREWS
SHIFT ROD
I.D. TAG
DIFFERENTIAL REMOVED
IDENTIFICATION
This unit contains an aluminum tag showing the model
number.
47
7
. Remove the output shaft assembly and the shifter/
3. The large beveled shifting gears can be placed onto
the shifter/brake shaft. The bevels on the gears
face each other and are separated with a neutral
spacer. Push shifting keys into the neutral spacer.
brake shaft assembly.
SHIFTER/BRAKE SHAFT
Then place a thrust washer, bronze bushing, and
an “O” ring on the shaft.
The spur gear, washer, bushing and “O” ring are
assembled to the other end of the shaft.
OUTPUT SHAFT REMOVED
8
. The input shaft can also be removed and inspected
or serviced. Remove the snap ring on the bevel
gear and pull the shaft through the case. The square
cut “O” ring must be replaced if the shaft is removed.
BEVEL GEARS
SPUR GEAR
Tool part No. 670251, is used for removal and
installation of needle bearings for the input shaft.
The needle bearing on the inboard side is installed
.
135 - .150” (3.43-3.81 mm) below flush.
SPACER
NOTE
Needle bearings are lubricated with E.P. grease. DO
NOT USE BENTONITE ON NEEDLE BEARINGS. For
maximum gear train life use only Bentonite grease on
all shafts and gears, Tecumseh part number 788067C.
INPUT
NEEDLE BEARING
SHAFT
FLUSH WITH
HOUSING
RETAINING RING
WASHER
FLAT SIDE
SQUARE CUT
"O" RING
BEVELED SIDE
NEEDLE
BEARINGS
4. Place the shifter/brake shaft assembly in the case.
.
.
135" (3.43mm)
150" (3.82mm)
BEVEL GEAR
THRUST
WASHER
RETAINING RING
REASSEMBLY
1
. Apply E.P. grease between the bearings in the
cover and install the input shaft, bevel gear and
snap ring.
5
. Place the output gear onto the output pinion. Install
the thrust washers and bushings.
OUTPUT GEAR
SHIFTER/BRAKE SHAFT
COLLAR
KEYS
2
. Grease both keyways and slide keys and collar
OUTPUT PINION
on shifter/brake shaft.
48
9
. Install the shifting fan with the pin in the groove of
the shifting collar. Grease the top of the shift fan.
Fill the unit with 18 oz. (532 ml) of Bentonite grease.
Install the top bearing block with the flange to the
right.
OUTPUT SHAFT ASSEMBLY
INPUT SHAFT
1
0. Clean the mating surfaces of the case and cover;
place a continuous thin bead of sealant all around
the seam. Use Loctite Gasket Eliminator #515,
Tecumseh part number 510334 or the Loctite Silicone
RTV 598, Tecumseh part number 788093.
LOWER BEARING BLOCK
FLANGE TO THE LEFT)
11. Make sure that the tabs of all the bushings are in
their “V” notches, install the cover and torque the
cap screws to 90-100 inch pounds (10.2-11.3 Nm).
(
6
. Insert the output shaft assembly into the case.
1
2. Reinstall the ball, spring and set screw on the models
that have them. The setting for the screw is flush
to the cover.
7. Prior to installing the differential into the case, apply
Bentonite grease to the axle bearing surfaces.
Check for binding by turning the input shaft.
BULL GEAR
BEVEL PINION GEAR ASSEMBLY
APPLY LUBRIPLATE
BRAKE
BRACKET
AXLE BEVEL GEARS
NOTE
The differential must be assembled out of the case
and then placed in the case.
8
. Insert the lower bearing block into the case with
the flange to the left. (See diagram on the top of
this page.) Place the center shaft with the bevel
pinion gears into the bull gear of the differential.
Center the bevel gear on the longest axle with the
pinion gears of the differential. This axle goes up
to the side of the bull gear where the center shaft
is located. On the opposite side of the bull gear,
center the bevel gear with the other axle. Pick up
the entire unit and place it in the case as an
assembly. Reposition the rubber seals on the ends
of the axles. (If damaged or old, replace them).
13. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install the brake assembly.
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch is
engaged. The brake and linkages may vary. Consult
the equipment owner's manual.
NOTE
With models that have an offset input, the differential
assembly begins with the shortest axle.
Follow recommended guidelines
WARNING
in equipment manufacturer's
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
SHIFTER FAN
RUBBER SEAL
49
910 SERIES TRANSAXLE
LUBRICATION
Permanent Lubrication
1
8 oz. (532 ml) of Bentonite grease
Part No. 788067C
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
50
CHAPTER 8. 915 SERIES / 940 SERIES TRANSAXLES
It is recommended that you take
WARNING
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
IDENTIFICATION TAG
DO NOT shift on a hill or when
WARNING
IDENTIFICATION
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
This unit contains an aluminum tag showing the model
number.
DISASSEMBLY OF TRANSAXLES
Use approved safety procedures
WARNING
with equipment for removal/
Clean the outside surface of transaxle. Position shift
lever in neutral as indicated by the shift pattern.
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
1. The unit may have the OEM option of a neutral
start switch, remove the switch.
2
. 915/940 Series transaxles will have a Allen head
setscrew, spring and detent ball. Remove these
and the cap screws that fasten the cover to the
case.
We caution you against the use
WARNING
of aftermarket variations of braking
systems, adjustments and service of these
components. Removing or altering factory installed
parts my affect performance and could result in
death or serious injury.
3. Push the shift rod through the cover and lift off.
Then remove the shifter assembly (which includes
the shift rod, and shifter fan) and lift out of case.
•
Servicing the braking system will void your
warranty. See your Authorized Tecumseh
Servicing Dealer.
4. Remove the “O” ring from the top of the shifter rod.
INDEX BALL AND
SPRING LOCATION
SHIFTER/BRAKE/
OUTPUT SHAFT
ASSEMBLY
OPTIONAL INPUT LOCATION
A INPUT
INPUT SHAFT
COVER/CASE HEX B INPUT
SCREWS (17)
COUNTERSHAFT
ASSEMBLY
SHIFT ROD
OPTIONAL SHIFT ASSEMBLY
ROD LOCATION
BRAKE BRACKET
SCREWS
SHIFT ROD
NEUTRAL START SWITCH LOCATION (OPTIONAL)
5. Remove the two brake bracket screws and remove
brake assembly.
GENERAL
6
. Remove the grease from the unit as the parts are
removed.
The 915 series transaxle has a sculptured case, gear
driven reverse and a unique power flow. The 915 series
has 3, 4, 5 or 6 speeds forward and 1 speed reverse.
The model pictured throughout this section utilizes
an A input. Assembly variations for models with a B
input or reverse input will be explained in the appropriate
segment.
NOTE
Bentonite grease may stain clothes. Care should be
used when handling.
51
9
40 SERIES
9. As these assemblies are taken apart, lay the parts
out in a systematic order. This will help to make
reassembly and inspection of parts easier. Clean
grease from each part as the parts are laid out. To
remove keys from the shifter/brake/output shaft you
must remove the large snap ring from its groove.
Be careful not to stretch or twist the snap ring; it
is not necessary to remove the snap ring from shaft.
The 940 Series is identical to the 915 Series with the
exception of 3 added bronze bushings. These bushings
is located on the shifter brake shaft one opposite the
brake rotor end. The other two are located on the spur
gear shaft, one on each end.
7
. Remove the bearing strap on the bull gear of the
differential. Remove the bull gear, bevel pinion gears
with center shaft, and the axles. Grasp the axle
bevel gears between your thumb and fingers, hold
together while lifting differential from the case.
SHIFTER/BRAKE SHAFT ASSEMBLY
BEARING STRAP
DIFFERENTIAL
BULL GEAR
AXLE BEVEL
GEAR
SNAP RING
1
0. The input shaft can also be removed and inspected
or serviced. Remove the snap ring on the bevel
gear and pull the shaft through the case. The square
cut “O” ring must be replaced if the shaft is removed.
8
. There are two (2) shaft assemblies in this transaxle;
the countershaft and the shifter/brake/output shaft
assembly. Remove these two shafts as complete
assemblies from the case.
Tool part No. 670251, is used for removal and
installation of needle bearings for the input shaft.
The needle bearing on the inboard side is installed
.
135 - .150” (3.43-3.81 mm) below flush.
NOTE
NOTE
Depending on the rotation of the countershaft gears,
the reverse idler assembly will be located either above
the reverse gears and held in place by bosses in the
cover or below the reverse gears and held in place by
bosses in the case. The reverse idler assembly will
always be located against the thrust of the countershaft
reverse gear.
NeedlebearingsarelubricatedwithE.P.grease.DO
NOT USE BENTONITE ON NEEDLE BEARINGS. For
maximum gear train life use only Bentonite grease on
all shafts and gears, Tecumseh part number 788067C.
INPUT
SHAFT
NEEDLE BEARING
FLUSH WITH
HOUSING
RETAINING RING
WASHER
SQUARE CUT
"O" RING
NEEDLE
BEARINGS
.
.
135" (3.43 mm)
150" (3.81 mm)
BEVEL GEAR
THRUST
WASHER
RETAINING RING
SHIFTER/BRAKE/
OUTPUT SHAFT
ASSEMBLY
COUNTERSHAFT
REVERSE IDLER
ASSEMBLY
ASSEMBLY
52
REASSEMBLY
LARGE BEVEL GEAR
OUTPUT GEAR
1
. Apply grease between the bearings in the cover
and install the input shaft, square cut seal, thrust
washers, bevel gear and snap ring.
SNAP RING GROOVE
THIN SHIFTING
WASHER
4
. On the Shifter/brake shaft the last shifting washer
will be a thin flat washer installed prior to the large
bevel gear. The style of input will determine how
the large bevel gear will be installed. In the model
pictured, input “A” is used and the bevel is inward
towards the keys. On models with a “B” input the
bevel will be outward or away from the keys.
SNAP RING
2
. Grease all keyways and slide keys and collar onto
the shifter/brake/output shaft. On models which
have a inner diameter recess cut into one side of
the shift collar, the recess side must face toward
the gears and snap ring for proper gear selection.
Place the large snap ring back into the snap ring
groove. On five speed models that do not use the
large bevel gear for the highest speed, an additional
neutral spacer will be placed between the snap
ring and the shift collar.
In both instances the gear cut directly onto the
large bevel gear will be toward the outside of the
case. Install a washer and then the output gear.
The output gear has an inner diameter recess on
one end, this recess must face toward the large
bevel gear. Two washers are installed next to the
output gear followed by a bronze bushing and rubber
“
O” ring. Then place a washer on the opposite end
REVERSE SHIFT GEAR
of the shaft to complete the assembly of the shifter/
brake shaft.
SHIFT GEARS
SHIFT WASHERS
REVERSE GEAR COLLAR
LOCATION FOR SPACER
SOME MODELS)
NEUTRAL SPACER
(
5
. The countershaft must have the longer unsplined
end toward the outside or brake side of the case
and the shorter unsplined end toward the shifter
assembly. The wide washer or spacer is placed
on the longer unsplined end followed by the largest
spur gear.
SHIFTING WASHER
CUT OUT SIDE
FLAT SIDE
NOTE
If assembling a six speed or on some five speed
models, a spacer will be placed next to the largest
spur gear. On all other models, leave a space the
width of the large bevel gear and then assemble
the remainder of the spur gears with the reverse
spur gear assembled with the collar side inward.
The small washer is placed next to the reverse
spur gear to complete the counter shaft assembly.
As all the gears are placed back into the assembly,
each should be packed with Bentonite grease.
3
. The shafts in this transaxle can be assembled
separately. After replacing the snap ring into its’
groove, place the reverse shifter gear onto the shaft
with the flat side next to the snap ring. Push the
shifting keys through the reverse gear and push
the neutral spacer over the end of the keys and
pull the neutral spacer and reverse gear up against
the snap ring. Next place the shifting gear onto
the shaft with the flat side next to the neutral collar.
The two assembled shafts can now be placed into
the transaxle case. If the model has the reverse
idler held in place by the case, insert the reverse
idler into the case prior to the shafts.
Then place a shifting washer onto the shaft with
the rounded edge towards the shifting keys.
Continue this procedure until all the gears and
washers have been added in their proper sequence.
53
NOTE
Clean the mating surfaces of case and cover; place
a continuous thin bead of sealant all around the
seam. Use Loctite Gasket Eliminator #515 ,
Tecumseh part number 510334 or the Loctite
Silicone RTV 598, Tecumseh part number 788093A.
Depending on the rotation of the countershaft gears,
the reverse idler assembly will be located either above
the reverse gears and held in place by the bosses in
the cover, or below the reverse gears and held in place
by the bosses in the case. The reverse idler assembly
will always be located against the thrust of the
countershaft reverse gear. Make sure that the tab on
the bronze bushing is located into the recess provided
in the case.
8
. Guide the cover over the shift rod and position onto
the case. Install the cover cap screws and torque
9
0-100 inch pounds (10.2-11.3 Nm). Install the
neutral start sensing switch if applicable. Replace
the square cut “O” ring on the exposed shift rod.
Check for binding by turning input shaft.
APPLY LUBRIPLATE
NOTE
The differential must be assembled out of the case
and then placed in the case. Apply Bentonite grease
anywhere the axle contacts the case.
BRAKE
BRACKET
6
. Place the center shaft with the bevel pinion gears
into the bull gear of the differential. Center the bevel
gear of one axle with the pinion gears of the
differential. Center the bevel gear of the other axle
to the pinion gears of the differential. Pick up the
entire unit and place it in the case as an assembly.
Reposition the rubber seals on the ends of the
axles in their bosses. (If damaged or old replace
them).
7
. Install the shifter assembly, bearing strap and reverse
idler assembly (if applicable). Pack the transaxle
with the remaining Bentonite grease (10 ounces
9. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flatwasher, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install brake assembly.
[
296 ml] total). Replace the spring, set screw and
the detent ball.
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch is
engaged. The brake and linkages may vary. Consult
the equipment owner's manual.
Follow recommended guidelines
WARNING
in equipment manufacturer's
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
54
915 SERIES / 940 SERIES TRANSAXLES
LUBRICATION
Permanent Lubrication
0 oz. (296 ml) of Bentonite grease
1
Part No. 788067C
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
55
CHAPTER 9. 920 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
DISASSEMBLY OF TRANSAXLE
WARNING
Clean outside surface of transaxle. Position shift lever
in neutral as indicated by the shift pattern.
1. The unit may have the OEM option of a neutral
start switch; remove the switch.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
2
. Removethe Allenheadsetscrew,springanddetent
ball. Remove the cap screws that fasten the cover
to the case.
DO NOT shift on a hill or when
WARNING
3. Push the shift rod through the cover and lift off.
Then remove the shifter assembly (which includes
the shift rod and shifter fan) and lift out of case.
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
NOTE
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
NOTE
Some models will have the index ball and spring on
the case end of the shift rod. Be careful not to lose
parts when removing shift rod assembly.
4. Remove the two brake bracket screws and remove
the brake assembly.
5. Remove the grease from the unit as the parts are
removed.
NOTE
Bentonite grease may stain clothes. Care should be
used when handling.
GENERAL
6
. Remove the top bearing block on the bull gear of
the differential. Remove the bull gear, bevel pinion
gears with center shaft and the axles. Grasp the
axle bevel gears between your thumb and fingers,
holding together while lifting differential from case.
The 920 series transaxle is very similar to the 900
series. The 920 series is available in 5, 6, or 7 speeds
forward and 1 speed reverse. The 7 speed transaxle
is shown in this section of this manual.
CASE COVER
INPUT SHAFT
HEX SCREWS
SHIFT ROD
A
B
ID TAG
IDENTIFICATION
This unit contains an aluminum tag showing the model
number.
56
7
. There are three (3) shaft assemblies in this transaxle;
the output shaft, the countershaft, and the shifter/
brake shaft assembly. Remove these assemblies
as complete as possible from the case.
REASSEMBLY
1. Apply grease between the bearings in the cover
and install the input shaft, square cut seal, thrust
washers, bevel gear and snap ring.
COUNTERSHAFT ASSEMBLY
OUTPUT SHAFT ASSEMBLY
SHIFTER/BRAKE SHAFT
SHIFT COLLAR
KEYS
2. Grease both keyways and slide the shift keys and
collar onto the shifter/brake shaft.
3
. The countershaft and the shifter/brake shaft should
be assembled at the same time. Start by placing
the reverse chain over the reverse sprockets. Make
sure the collars on the sprockets are on the same
side of the chain and install the sprocket onto the
shifter/brake shaft with the collar away from the
shift keys.
SHIFTER/BRAKE SHAFT ASSEMBLY
8
. As these assemblies are taken apart, lay the parts
out in a systematic order. This will help to make
reassembly easier and inspection of all parts
possible. Clean each part of grease as the parts
are laid out.
LARGE
LARGER
INNER
RADIUS
DIAMETERS
SPACER
FACE EACH
TOWARD
OTHER
SHIFT KEYS
REVERSE CHAIN AND
SPROCKETS
SPROCKET
COLLARS
9
. The input shaft can also be removed and inspected
or serviced. Remove the snap ring on the bevel
gear and pull the shaft through the case. The square
cut “O” ring must be replaced if the shaft is removed.
Tool part No. 670251, is used for removal and
installation of needle bearings for the input shaft.
The needle bearing on the inboard side is installed
.
135" - .150" (3.43-3.81 mm) below flush.
NEUTRAL SPACER
Next place the neutral spacers onto the shifter/
brake shaft with larger inner diameter sides facing
together, and the spacer with the largest inner
diameter radius toward the shift keys. Push the
shifting keys through the reverse sprocket and the
first neutral spacer. Pull the neutral spacers and
the reverse sprocket up against the shoulder of
the shifter/brake shaft.
INPUT
SHAFT
NEEDLE BEARING
FLUSH WITH
HOUSING
RETAINING RING
WASHER
SQUARE CUT
"O" RING
NEEDLE
BEARINGS
.
.
135" (3.43 mm)
150" (3.81 mm)
NOTE
BEVEL GEAR
There have been a few 900 models built with identical
neutral collar halves. These can be installed in either
direction.
THRUST
WASHER
RETAINING RING
NOTE
Needle bearings are lubricated with E.P. grease. DO
NOT USE BENTONITE on needle bearings. For
maximum gear train life use only Bentonite grease on
all shafts and gears, Tecumseh part number 788067C.
57
*
4.Insert the countershaft into the smaller reverse
sprocket. Insert a thin thrust washer next to the
sprocket (collar side) and then install the large bevel
gear with the bevel towards the reverse sprocket.
Place another thin thrust washer on the back side
of the bevel gear.
SPACER
NOTE
As all the gears are placed back onto the assembly,
each should be packed with bentonite grease.
BEVEL GEAR
COUNTERSHAFT
SPUR GEAR
"O" RING
6
. Place the spacer on the countershaft next to the
reverse sprocket. Then place a thrust washer on
each end of the countershaft and insert the bronze
bushings.
Place the large washer on the end of the shifter/
brake shaft, followed by the bronze bushing and
the “O” ring.
7
. Place the spur gear onto the splines on the other
end of the shifter/brake shaft. The thin washer,
bushing, and “O” ring conclude the assembly of
these two shafts.
WASHER
WASHER
OUTPUT PINION
SHIFTING WASHER
CUT OUT SIDE
FLAT SIDE
BUSHING
BUSHING
OUTPUT GEAR
5
. Build the gears on the countershaft and shifter/
brake shaft alternately, meshing each gear with
it’s mating gear on the opposite shaft. The first
gear on the shifter/brake shaft would be the largest
of the shift gears. Place this gear next to the neutral
collar with the flat side of the gear next to the collar.
8. Place the output gear on the stepped end of the
output pinion. Place the thrust washers and the
bronze bushings on the ends of the output shaft.
Install these three shaft assemblies back into the
case. Make sure that the tabs of all bushings are
in their “V” notches in the case.
(
See the drawing on the prior page).
Then place a shifting washer onto the shifter/brake
shaft with the rounded edge towards the shifting
keys. Continue this procedure until all the gears
on both shafts have been added.
NOTE
The differential must be assembled out of the case
and then placed in the case. Apply bentonite grease
to axle contact areas of case.
NOTE
It is not only important that gears match up according
to diameter, but also to thickness.
*
ASSEMBLY VARIATIONS
On models which are driven from the opposite side of
the input bevel gear, the following changes take place.
A slightly thicker large bevel gear is placed on the
countershaft with the bevel facing the spur gears and
in the previous location of the spacer. The thickness
of the gear eliminates the need for the washers on
each side of the large bevel gear. The reverse chain
o
and sprocket are also turned 180 , which places the
sprocket collars away from shifting gears and spur
gears. The spacer is then placed in the previous location
of the large bevel gear next to the reverse sprocket.
58
1
2. Guide the cover over the shift rod and position onto
CENTER SHAFT
the case. Install the cover cap screws and torque
BEVEL GEAR
9
0-100 inch pounds (10.2-11.3 Nm). Install the
neutral start sensing switch if applicable. Replace
the square cut “O” ring on the exposed shift rod.
Replace the detent ball, spring and set screw and
turn set screw one (1) turn below flush. Install the
neutral start sensing switch if applicable.
BEVEL GEAR
BEVEL PINION
GEARS
Check for binding by turning the input shaft.
BULL GEAR
APPLY LUBRIPLATE
9
. Place the center shaft with the bevel pinion gears
into the bull gear of the differential. Center the bevel
gear on the longest axle with the pinion gears of
the differential. Center the bevel gear of the other
axle on the other side. Pick up the entire unit and
place it in the case as an assembly. Reposition
the rubber seals on the ends of the axles in their
bosses. (If damaged or old replace them).
BRAKE
BRACKET
1
3. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flat washer, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install brake assembly.
1
0. Install the shifter assembly and bearing strap, pack
the transaxle with the remaining Bentonite grease
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch
is engaged. The brake and linkages may vary.
Consult the equipment owner's manual.
(
30 ounces [887 ml] total). Apply grease to the
top of the shifter fan.
Follow recommended guidelines
in equipment manufacturer's
WARNING
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
1
1. To seal the case and cover at the end of the shifter/
brake shaft, a flat plug is placed on the opposite
end of the brake assembly. Clean the mating
surfaces of case and cover; place a continuous
thin bead of sealant all around the seam. Use Loctite
Gasket Eliminator # 515, Tecumseh part number
5
10334 or the Loctite Silicone RTV 598, Tecumseh
part number 788093A.
59
920 SERIES TRANSAXLES
LUBRICATION
Permanent Lubrication
3
0 oz. (887 ml) of Bentonite grease
Part No. 788067C
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
60
CHAPTER 10. 930 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
IDENTIFICATION
WARNING
This unit contains an aluminum tag showing the model
number.
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
COVER CASE
HEX SCREWS
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
BRAKE BRACKET SCREWS
Use approved safety procedures
WARNING
DISASSEMBLY OF TRANSAXLE
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
Clean outside surface of transaxle. Position shift lever
in neutral as indicated by the shift pattern.
1. The unit may have the OEM option of a neutral
switch; remove the switch.
2
. Removethe Allenheadsetscrew,springanddetent
ball. Remove the cap screws that fasten the cover
to the case.
NOTE
Due to the many variations of equipment braking
systems, adjustments and repair to these components
and linkages are not considered warranty.
3
. Push the shift rod through the cover and lift off.
Then remove the shifter assembly (which includes
the shift rod, and shifter fan) and lift out of case.
INPUT SHAFT
DIFFERENTIAL
BEARING STRAP
IDENTIFICATION TAG
INDEX BALL,
SPRING AND
SET SCREW
OUTPUT SHAFT
ASSEMBLY
SHIFT ROD
SHIFTER/BRAKE
SHAFT ASSEMBLY
COVER/CASE
HEX SCREWS
BRAKE BRACKET SCREWS
(BRAKE CAN BE ON RIGHT
OR ON LEFT SIDE)
COUNTERSHAFT
ASSEMBLY
NEUTRAL START SWITCH
LOCATION (OPTIONAL)
SHIFTER ASSEMBLY
LOCATION
4
. Remove the “O” ring from the top of the shifter rod.
GENERAL
5. Remove the two brake bracket screws and remove
brake assembly.
The 930 series transaxle is very similar to the 920
series. The 930 series is available in 3 through 7 speeds
forward and 1 speed reverse. The model pictured
throughout this section is the most popular type. There
are models which operate in the opposite direction
without changing the input location. Throughout this
section an asterik (*) will direct the reader to the end
of the section where the differences between these
models are explained.
6. Remove the grease from the unit as the parts are
removed.
NOTE
Bentonite grease may stain clothes. Care should be
used when handling.
61
BEARING STRAP
INPUT
SHAFT
NEEDLE BEARING
FLUSH WITH
HOUSING
DIFFERENTIAL
BULL GEAR
RETAINING RING
WASHER
SQUARE CUT
"O" RING
AXLE BEVEL
GEAR
NEEDLE
BEARINGS
.
.
135" (3.43 mm)
150" (3.81 mm)
BEVEL GEAR
THRUST
WASHER
RETAINING RING
1
0. The input shaft can also be removed and inspected
or serviced. Remove the snap ring on the bevel
gear and pull the shaft through the case. The square
cut “O” ring must be replaced if the shaft is removed.
7
. Remove the bearing strap on the bull gear of the
differential. Remove the bull gear, bevel pinion gears
with center shaft and the axles. Grasp the axle
bevel gears between your thumb and fingers and
hold together while lifting differential from case.
Tool part No. 670251, is used for removal and
installation of needle bearings for the input shaft.
The needle bearing on the inboard side is installed
.
135 - .150” (3.43-3.81 mm) below flush.
OUTPUT SHAFT
ASSEMBLY
COUNTERSHAFT ASSEMBLY
NOTE
Needle bearings are lubricated with E.P. grease. DO
NOT USE BENTONITE on needle bearings. For
maximum gear train life use only Bentonite grease on
all shafts and gears, Tecumseh part number 788067C.
REASSEMBLY
1
. Apply grease between the bearings in the cover
and install the input shaft, square cut seal, thrust
washers, bevel gear and snap ring.
SHIFTER/BRAKE SHAFT
SHIFT COLLAR
SHIFTER/BRAKE SHAFT ASSEMBLY
8
. There are three (3) shaft assemblies in this transaxle;
the output shaft, the countershaft, and the shifter/
brake shaft assembly. Remove these assemblies
as complete as possible from the case.
KEYS (2 OR 4)
SNAP RING
2
. Grease all keyways and slide keys and collar onto
the shifter/brake shaft. (There are both 2 and 4
key models). Place the large snap ring back into
the snap ring groove. On models which have an
inner diameter recess cut into one side of the shift
collar, the recess side must face toward the gears
and snap ring for proper gear selection.
SNAP RING GROOVE
SNAP RING
9
. As these assemblies are taken apart, lay the parts
out in a systematic order. This will help to make
reassembly easier and inspection of all parts
possible. Clean each part of grease as the parts
are laid out.
To remove keys from the shifter/brake shaft you
must first remove the large snap ring from the snap
ring groove. Be careful not to stretch or twist the
snap ring; it is not necessary to remove the snap
ring from the shaft.
62
N AND
R
THRUST
WASHER
SPACER
BUSHING
SPROCKET COLLARS
NEUTRAL SPACER
SNAP RING
WASHER
BUSHING
THRUST WASHER
*
3. To assemble this transaxle the countershaft and
the shifter/brake shaft should be assembled at the
same time. Start by placing the reverse chain over
the reverse sprockets. Make sure that the collars
on the sprockets are on the same side of the chain.
Install a large washer onto the shifter/brake shaft
next to the snap ring and then the large sprocket
with the collar away from the shifting keys. Push
the shifting keys through the reverse sprocket and
push the neutral spacer over the end of the keys.
Pull the neutral spacer and reverse sprocket up
against the snap ring on the shifter/brake shaft.
"O" RING
WASHER
*6. Place the spacer on the countershaft next to the
reverse sprocket. Then place a thrust washer on
each end of the countershaft and insert the bronze
bushings.
Place the large washer on the end of the shifter/
brake shaft, the bronze bushing and the “O” ring.
BEVEL GEAR
WASHER
WASHER
SPUR GEAR
COUNTERSHAFT
SPUR GEAR
WASHER
*
4. Insert the countershaft into the smaller reverse
sprocket. Insert a thin thrust washer next to the
sprocket (collar side) and then install the large
bevel gear with the bevel towards the reverse
sprocket. Place another thin thrust washer on the
back side of the bevel gear.
BUSHING
7
. Place the spur gear onto the splines on the other
end of the shifter/brake shaft. The thin washer and
bushing conclude the assembly of these two shafts.
NOTE
As all the gears are placed back into the assembly,
each should be packed with Bentonite grease.
WASHER
WASHER
SPUR GEARS
BUSHING
BUSHING
OUTPUT
PINION
SHIFT GEARS SHIFTING CUT OUT FLAT
SHIFT WASHERS
OUTPUT GEAR
WASHER
SIDE
SIDE
5
. Build the gears on the countershaft and shifter/
brake shaft alternately, meshing each gear with
its mating gear on the other shaft. The first gear
on the shifter/brake shaft would be the largest of
the shifting gears. Place this gear next to the neutral
spacer with the flat side of the gear next to the
spacer.
8. Place the output gear on the stepped end of the
output pinion. Place the thrust washers on each
end and then the bronze bushings. Install these
three shaft assemblies back into the case. Make
sure that the tabs of all the bushings are in their
“
V” notches in the case.
Then place a shifting washer onto the shifter/brake
shaft with the rounded edge towards the shifting
keys. Continue this procedure until all the gears
on both shafts have been added.
NOTE
It is not only important that gears match up according
to diameter, but also to thickness.
*
See Assembly Variations on page 64
63
CENTER SHAFT
APPLY LUBRIPLATE
BEVEL GEAR
BRAKE
BRACKET
BEVEL GEAR
BEVEL PINION GEARS
BULL GEAR
NOTE
The differential must be assembled out of the case
and then placed in the case. Apply bentonite grease
to axle contact areas of case.
1
2. Apply a light film of lubriplate to the inside lever
which contacts the brake pins, the outside of the
lever which contacts the flat washer, and between
the shaft O.D. and the I.D. of the splined brake
disc. The brake pads and brake disc must be free
of grease and oil. Install brake assembly.
9
. Place the center shaft with the bevel pinion gears
into the bull gear of the differential. Center the bevel
gear on the longest axle with the pinion gears of
the differential. Center the bevel gear on the other
axle with the other side. Pick up the entire unit
and place it in the case as an assembly. Reposition
the rubber seals on the ends of the axles in their
bosses. (If damaged or old replace them).
Install the transmission on the equipment. Adjust
the brake linkage to disengage when the clutch
is engaged. The brake and linkages may vary.
Consult the equipment owner's manual.
Follow recommended guidelines
in equipment manufacturer's
WARNING
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
*
ASSEMBLY VARIATIONS
1
0. Install the shifter assembly and bearing strap, pack
the transaxle with the remaining Bentonite grease
On models which are driven from the opposite side
of the input bevel gear the following changes take
place.
(
30 ounces total) (887 ml). Apply grease to the
top of the shifter fan.
A slightly thicker large bevel gear is placed on the
countershaft with the bevel facing the spur gears
and in the previous location of the spacer. The
thickness of the gear eliminates the need for the
washers on each side of the large bevel gear, which
places the sprocket collars away from the shifting
gears and spur gears. The reverse chain and sprocket
o
is also turned 180 . The spacer is then placed in
the previous location of the large bevel gear next
to the reverse sprocket.
1
1. To seal the case and cover at the end of the shifter/
brake shaft, a flat plug is placed on the opposite
end of the brake assembly. Clean the mating
surfaces of case and cover; place a continuous
thin bead of sealant all around the seam. Use Loctite
Gasket Eliminator # 515, Tecumseh part number
5
10334 or the Loctite Silicone RTV 598, Tecumseh
part number 788093A. Install cover screws and
torque to 90-100 inch pounds (10.2-11.3 Nm).
Replace the detent ball, spring and set screw and
turn set screw one (1) turn below flush. Install the
neutral start sensing switch if applicable.
Check for binding by turning input shaft.
64
930 SERIES TRANSAXLES
LUBRICATION
Permanent Lubrication
3
0 oz. (887 ml) of Bentonite grease
Part No. 788067C
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
65
CHAPTER 11. MST200 SERIES TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
IDENTIFICATION
WARNING
The MST has a decal placed at the rear of the unit
and to the right of the differential gear section. This
makes it easily visible without having to remove any
obstructions to view it.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
Use approved safety procedures
WARNING
IDENTIFICATION TAG
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
STEPS TO TAKE BEFORE DISASSEMBLY.
1
. Clean the outside surface of the transaxle.
. Position the shift lever in the neutral position.
2
We caution you against the use
WARNING
of aftermarket variations of braking
systems, adjustments and service of these
components. Removing or altering factory installed
parts my affect performance and could result in
death or serious injury.
•
Servicing the braking system will void your
warranty. See your Authorized Tecumseh
Servicing Dealer.
SQUARE CUT O-RING
AND PUSH NUT
REMOVE FILL PLUG
3
. Remove the oil drain / fill plug located on top of the
unit. This can be done by using a needle nose
pliers to pull the plug out. Drain all of the oil from
the unit.
CUSTOMER
MOUNT POINTS
4. Remove the neutral start switch, if installed (O.E.M.
option).
(PRY POINT)
GENERAL
5
. Remove the push nut (if equipped) and square cut
The MST (Manual Shift Transaxle) 200 is a sealed
unit which uses 16 oz. (473 ml) of 80W90 gear lube
"
O" ring, from the top of the shift fork shaft.
(
part #730229B). The MST series is available with up
to 6 speeds forward and one reverse. It has a contoured
case and cover. Its unique gear design system uses
the input gear to drive both the forward and reverse
motion. It also eliminates the recess previously found
on shifter brake shaft spur gears.
Thrust washers are used on all transaxles to protect
stationary surfaces from rotating surfaces. To determine
the location of the thrust washer, check its inside
diameter and compare it to the outside diameter of
the shaft. If the fit is loose, it is out of position. The flat
washer used on the shifter shaft (brake end) must
have a diameter large enough to stop the keys from
going past the end of the gear slots.
ALLEN HEAD SET SCREW
SPRING
DETENT BALL
6. Remove the set screw, spring and detent ball.
66
DISASSEMBLY
SEAL
BUSHING CHAMFERED SHIFT WASHERS
1.
Remove the self-tapping hex head screws that hold
the cover to the case and the two center screws
located on the bottom (case side) of the transaxle.
THRUST WASHER
When prying the crankcase from
CAUTION
the crankcase cover use specified
THRUST WASHER
mount points. Failure to do so may result in
equipment damage.
SPUR GEAR
2
.
With a rubber or leather mallet tap down on the
shift lever rod while removing the cover from the
case.
NOTE: INSIDE RECESS FACES KEYS
7.
To disassemble the shifter/brake shaft, start on
the spur gear side. Remove the oil seal, the bronze
bushing and thrust washer. Remove all of the shifter
spur gears (and spacers if used) and shift washers.
Remove the neutral collar, reverse gear and thrust
washer. On the output side of the shifter/brake
shaft remove the bronze bushing, thrust washer,
and output spur gear.
NOTE
If rust has occurred on the shaft, remove it with emery
cloth before removing the shaft to prevent damage.
3
.
Remove the two brake bracket screws and remove
the brake assembly.
4.
Remove the differential ring gear, and bevel pinion
gears with the center shaft drive pin and the axles.
Grasp the axle bevel gears between your thumb
and fingers. Hold the entire assembly together while
lifting the differential from the case.
To remove the shift keys from the shifter/brake
shaft, you must first expand the large snap ring
from the snap ring groove. Be careful not to stretch
or twist the snap ring, it is not necessary to remove
the snap ring from the shaft. Place the expanded
snap ring onto the shifter/brake shaft and slide
the shift keys and shift collar off the shifter/brake
shaft.
NOTE: When a "B" input is used the input bevel gears will be
opposite of this picture. The drive spline on this shaft also
moves.
NOTE: When a "B" input is used the input bevel gears will be
opposite of this picture. The drive spline on this shaft also
moves.
REVERSE FOR B INPUT
REVERSE DRIVE BEVEL GEAR
FORWARD DRIVE BEVEL GEAR
5
.
There are three shaft assemblies in this transaxle.
The countershaft, shifter/brake shaft and output
shaft. Remove the shifter fork assembly and then
remove the shaft assemblies from the case.
8
. To disassemble the counter spur gear shaft, remove
the bushing, thrust washer and spur gears (and
spacers if used) the last spur gear is held in place
by a retaining ring. Remove the retaining ring and
slide the spur gear and forward drive bevel gear off
the splined end of the shaft. The bushing, thrust
washer and reverse drive bevel gear can be removed
from the unsplined end of the shaft.
NOTE
Before you begin disassembly, ask the customer if
the unit has been serviced previously by a technician
or perhaps himself. They may have misassembled it.
6.
As these assemblies are taken apart, lay the parts
out in a systematic order. This should help to make
the reassembly easier.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
67
REASSEMBLY
SPACER
The tool, part number 670251 can also be used for
installation of the needle bearings for the input shaft.
The inside needle bearings are installed .135" -.150"
(
3.43-3.81 mm) below flush. The top bearing is installed
flush to the casting.
1
. Use an EP bearing grease and apply it to the
bearings in the cover. Place the seal into the cover
with the grooved side of the seal visible and facing
the installer. Place the snap ring and thrust washer
on the input shaft and slide the shaft through the
cover and seal. Place the square cut o-ring, thrust
washer and input bevel gear on the shaft on the
inboard side and secure them by placing a snap
ring in the snap ring groove.
THRUST WASHERS
9
. To disassemble the output shaft, remove the bushing,
thrust washer, large output spur gear, spacer, small
output spur gear, thrust washer, and bushing.
SNAP RING
INPUT
NEEDLE BEARING
SHAFT
FLUSH WITH
HOUSING
RETAINING RING
NEUTRAL COLLAR
WASHER
OIL SEAL
RECESS IN KEY COLLAR
SPUR GEAR SPLINE
NEEDLE
BEARINGS
.
.
135" (3.43 mm)
150" (3.81 mm)
BEVEL GEAR
2. Next assemble the shifter brake shaft by placing
the shift keys in the keyway on the shaft with the
tip of the keys facing the shifter spur gear side of
the shaft. Extend the collar end of the key slightly
beyond the shaft. Place the shift collar in the notch
provided on the shift key with the inside diameter
recess on the collar facing toward the tips of the
keys. Place the notch from the second key on the
inside diameter of the shift collar and position the
key in the slot on the shifter/brake shaft. Slide the
keys and the collar onto the shaft under the snap
ring. Place the snap ring back into the groove on
the shaft.
THRUST
WASHER
RETAINING RING
1
0. The input shaft can also be removed and inspected
or serviced. Remove the snap ring and thrust washer
on the input shaft, pull the shaft through the cover.
The oil seal located on the inboard side of the cover
should be replaced when reassembled. Be sure to
reinstall the upper and lower thrust washers. Tool
part number 670251 is used for removal of needle
bearings for the input shaft.
SEAL
BUSHING
1
1. After clean up of all parts, a complete inspection
SHIFTER WASHERS
should be done. Check for chipping or damage to
the gear teeth, keys or the four key slots in the
shifter gears. You also should inspect the two
keyways in the shifter shaft for damage, or chipping.
Worn or damaged parts must be replaced.
THRUST WASHER
THRUST WASHER
SPUR GEAR
SNAP RING
NOTE: INSIDE RECESS FACES KEYS
3
. Place the plain large thrust washer over the key
tips on the spur gear side of the shaft next to the
snap ring. The sequence that follows is reverse
gear, the neutral collar, then 1st thru the number
of gears the unit contains (largest to smallest).
Between each gear place a shift washer with the
chamfered I.D. facing the shift key (opposite the
brakeshaft).
68
on the splined shaft with the bevel facing the reverse
drive gear. A retaining ring is put on the shaft next
to the spur gear between the splined sections to
prevent the bevel gears from spreading.
The countershaft is then completed by placing the
remaining spur gears on the shaft (smallest to
largest). If the spacers are used they will be placed
between the final spur gear and the thrust washer
with the bushing to follow.
NOTE
The spur gears on the countershaft can be installed
in either direction.
SPACER
SHIFTING WASHER
OLD STYLE
NEW STYLE
NOTE
Reverse and first gear do not have a shift washer; the
neutral collar compresses the key here. Shift washers
have one side where the inside diameter is rounded,
this rounded edge must face the shift keys. The shifter
spur gears no longer have a recess on one side and
do not require that they be positioned in any particular
direction. Units that have less than six speeds will
use a spacer in place of a gear. When this occurs it
is not required to have a shift washer between the
spacer and the preceding gear.
THRUST WASHERS
5
. The output shaft is completely splined and consists
of a bronze bushing, thrust washer, a large output
gear, spacer, small output gear, thrust washer and
bronze bushing.
When the final spur gear or spacer is in place, a
thrust washer is positioned on the shaft to protect
the case from the rotating gear. This washer is
slightly larger then the diameter of the spacer and
large enough to cover the inside diameter of the
key slot portion of the shifter spur gear. Next place
the bronze bushing and the oil seal on the shaft
DIFFERENTIAL
ASSEMBLY
(
the open side of the seal must face inward). This
completes the spur gear side of the shifter brake
shaft. The output side only requires the output spur
gear, washer and bushing.
RETAINING CLIP
6
. To reassemble the differential, first inspect the axle
bevel gears for damage or wear. If it is necessary
to replace a gear, the mating gears must also be
replaced.
The differential must be assembled outside of the
case and placed into the case as an assembly.
Using seal protector (part # 670262) place a new
seal on each shaft with the open side facing inward.
Hold the longest shaft with the bevel gear and washer
in your hand between the ring and middle finger.
Place the bull gear and the bevel pinion gears and
shaft on top of the axle shaft and bevel gear. Center
the pinion gear shaft on the axle shaft and place
the short axle so it is also centered on the pinion
shaft.
REVERSE FOR "B" INPUT
4
. To assemble the countershaft, place the reverse
input bevel gear on the unsplined end of the shaft.
Follow with a washer and a bronze bushing to
complete the reverse drive side of the countershaft.
The forward drive side requires the forward input
bevel gear and the smallest spur gear to be placed
69
1
0. Place a coating of grease on the shaft for easy
assembly and corrosion protection. Replace the
"
O" ring if needed. With the cover in position over
the shaft, place it onto the case and rotate the
input shaft to allow the gears to mesh, and drop
the cover into place.
SEAL LOCATION
1
1. Install the cover screws and torque them to 90-
7
. Pick up the entire assembly and place it into the
case, positioning the seals in the seal pockets.
When properly installed, the axle shaft should turn
freely without any binding.
1
00 inch pounds (10-11.3 Nm). Replace the detent
ball, spring and set screw. Turn the set screw down
to the flush position. Install the neutral start sensing
switch if applicable.
NOTE
Before closing the case make sure the case and cover
fit together evenly. Insure the bushings are properly
positioned with the flat sides of the bushings matching
the pockets of the case and cover.
LOCTITE BEAD AROUND
OLD STYLE" SEALS
SEALANT AROUND TWO BOLTS
FROM BOTTOM OF CASE
"
ALLEN HEAD SET
SCREW
SPRING
DETENT BALL
NOTE: Detent screw must have pipe thread sealant applied to
prevent oil leakage.
NOTE
Do not forget to re-install the two bottom bolts.
1
2. Prior to installing the brake assembly, apply a light
film of lubriplate to the inside of the lever portion
which contacts the pins, the outside lever which
contacts the flat washer, and between the shaft
O.D. and bore of the brake disc. Brake pads and
the brake disc must be free of grease and oil. Install
the brake assembly.
NEW "RIBBED" STYLE SEALS DON'T NEED SEALANT
Avoid blocking oil passages
leading to axle shafts when
WARNING
applying a silicone bead to case as shown. Failure
to do so may result in oil leaks and could result
in death or serious injury.
OIL FILL/DRAIN HOLE
8
. To seal the case and cover, clean the mating surfaces
and place a continuous thin bead (1/16" / 1.5 mm)
of Loctite 598 Silicone RTV (part # 788093A) around
the entire perimeter of the cover to prevent an oil
leak. Don't forget the two bottom bolts.
NOTE
The axle and brake shaft seals on later production
MST's have been redesigned to eliminate the need
for sealant in the seal/bearing pocket area. These
new seals are identified by external ribs that hold the
seal in place and prevent leakage. DO NOT put sealant
in the seal/bearing pockets with this new type of seal.
13. Refill the transaxle through the fill hole located in
the cover. This unit requires 16 oz. (473 ml) of 80W90
gear lube (part #730229B). When completed,
lubricate the plug lightly on the outside with oil.
Use a 3/16" (4.7 mm) wood dowel placed in the
plug recess to push it into the plug hole.
"O" RING
1
4. Install the transaxle on the equipment. Make any
clutch and brake adjustments in accordance with
the equipment manufacturers owners manual.
Follow recommended guidelines
in equipment manufacturer's
WARNING
manual for correct brake adjustment. Failure to
do so could result in excessive brake pad wear
and brake failure which could result in equipment
damage, death or serious injury.
9
. Before placing the cover on the case, place the
shift rod and fork pins into the shift collar and the
shaft into its' boss in the case. Inspect the shaft
on the rod and fork for rust and burrs.
70
CHECKING OIL LEVEL
PROCEDURE:
6. If oil is needed, we recommend using a 16 ounce
473 ml) goose neck mechanics oil can. (These
(
1. Place the tractor on a level surface.
are readily available at any hardware store.) Fill
the unit with all 16 ounces (473 ml) of 90 wt.
gear oil to the level indicated.
2
. Depress the clutch/brake pedal, engage parking
brake and place the deck in lowest cutting position.
7
. Reinstall the plug by lubricating it with a silicon
spray lubricant. An installation tool can be made
by using one of the following procedures.
3
. Locate the rubber fill plug next to the shift rod as it
enters the transaxle cover.
6
" (152 mm)
FILL PLUG
2
0" (508 mm)
ROUNDED END
3"
76 mm)
(
FILL PLUG PUSHER TOOL
/16" (4.76 mm) ROD
3
4
. Work a needle nose pliers under the lip of the plug,
rocking from side to side until plug is removed.
Use care to not damage the rubber plug.
8. When the plug is accessible from the battery box
area, make an installation tool from 3/16" (4.76
mm) cold rolled steel rod as shown.
DIPSTICK
NO. 35942
LARGE FENDER
WASHER
1
/2" (12.7 mm) CONTACT IS FULL
o
5
4
STD. NO. 10 NUT
NO. 10 SCREW BOLT
" (50 mm) LONG
2
9
. If working from the bottom or side, use a No. 10
bolt screw approximately 2 inches (50 mm) long
with full threads. Then find a large fender washer
and nut for the screw. The washer will give your
fingers a large surface area to push down on for
reinstallation of the plug. The blunt end of a TORX
5
. Insert the dipstick gauge at a 45° angle (Part Number
5942). Check for approximately 1/2 inch (12.7
mm) of oil when fully inserted. This is 16 ounces
473 ml) of EP90 gear oil.
3
(
3
0 bit works well also.
71
CHAPTER 12. 1200 SERIES THREE-SPEED TRANSAXLES
H-SHIFT PATTERN
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
DISASSEMBLY
WARNING
1. Position the shifter forks in neutral.
2
. When disassembling the unit, it should be held so
it lies on the case, and properly blocked so no
weight rests on the input shaft or differential, but
keeping the case rigid.
When shifting gears verify the
WARNING
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
The unit also needs to be held in a vice in such a
way that it can be worked on without the chance
of falling, or causing injury.
DO NOT shift on a hill or when
WARNING
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
3
. Oil seals have a double lip so seal sleeves do not
offer much protection during removal. Upon
reassembly new seals should be used.
Use approved safety procedures
WARNING
4. Tap dowel pins into the case and remove socket
head cap screws.
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
OUTPUT GEAR
AXLE
CASE
We caution you against the use
WARNING
of aftermarket variations of braking
systems, adjustments and service of these
components. Removing or altering factory installed
parts my affect performance and could result in
death or serious injury.
THRUST
WASHER
•
Servicing the braking system will void your
warranty. See your Authorized Tecumseh
Servicing Dealer.
SPACER
GENERAL
5. Lift the cover off of the case. Discard the gasket.
Remove output gear and shaft.
1
. The 1200 series transaxle has three forward speeds
and one reverse.
SHIFTING ASSEMBLY
AXLE SUPPORT TO CASE/COVER
SEAL
AXLE
HOUSING
BUSHINGS
PRESS FIT
2
. This series is not intended for use with ground
engaging equipment. That is, it should not be used
to pull plows, tillers or similar equipment. Care is
to be used and common sense is expected in any
situation where a severe strain will be placed on
the axles.
6. Remove the shifting assembly as one unit.
1
200Housing, BushingandSealAssy.
On the 1200 series, replace the seals after complete
reassembly.
72
INSPECTION AND REPAIR
REVERSE IDLER
GEAR SHAFT AND
SPACER
Inspection of the case and cover on the 1200 series
may indicate the need for replacement of the axle
housings. Use an arbor press to drive out the housing,
and a protective piece of bar stock between the housing
and press when replacing the housing. Press the housing
in squarely until the flange seats against the case
and cover.
ASSEMBLY
1
. Install the input shaft in the case. Use a soft mallet
to seat the shaft and gear completely. Binding can
occur if the shaft is driven in only part way.
INPUT SHAFT
AND GEAR
2
. Install the differential assembly. The four cap screw
heads should face away from the output gear or
downward.
7. Remove the reverse idler shaft, spacer and gear.
GEAR CLUSTER
ASSEMBLY
BEVEL EDGE
DOWN
SPACER
BEVEL EDGE OF
TOOTH TOWARD
LARGE GEAR
8. Lift out the three gear cluster.
INPUT SHAFT
AND GEAR
3
. Install the three gear cluster, with the smallest gear
facing up.
INPUT SHAFT
DIFFERENTIAL
NOTE
CHAMFER
TOWARD
BEARING
Bevels of the small and middle gears go down toward
the large gear with the large gear bevel facing up. The
short spacer goes between the large and middle gears.
REVERSE IDLER
GEAR SHAFT AND
SPACER
OUTSIDE END
OF INPUT
SHAFT
9. Remove the input shaft, then the differential.
NOTE
Note what the relationship of the bolt heads are prior
to removal of the assembly.
INPUT SHAFT
AND GEAR
4
. Position the reverse idler shaft in the unit; then
install the gear and spacer.
73
LUBRICATION
Use S.A.E. 90 E.P. oil in the transaxle.
Fill units 1203, 1204, 1204-A, and 1205 thru 1208 with
3
pints (1420 ml) of oil. All other units, fill with 2 pints
(
946 ml)of oil.
SQUEEZE TOP
OF SHIFT
RODS
5
. Install the shifter assembly as a unit into the case.
When installed correctly, the neutral square formed
by the shifting forks should appear through the case
opening for attaching the shift housing. Both shift
gears should be out of mesh.
OUTPUT GEAR
AXLE
CASE
THRUST WASHER
SPACER
6.
7.
8.
Install the output shaft, gear, spacer and thrust
washer.
Position a new gasket on the cover mounting
surface; then install the cover.
Align the cover with the dowel pin and secure with
the socket head cap screw. Torque to 10 ft. lbs.
(
13.6 Nm).
9.
Install the axle seals using a sleeve and driver.
1
0. Install the axle supports. Be sure the mounting
pad position is correct before tightening down the
cap screws to 13 ft. lbs. (17.7 Nm).
1
1. Install a new gasket and shift lever housing. Torque
screws to 10 ft. lbs. (13.5 Nm). Be sure the shift
lever is in the proper position to allow shifting.
74
CHAPTER 13. HYDROSTATIC GEAR REDUCTION DIFFERENTIALS
1
300 SERIES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
WARNING
EQUIPMENT
MOUNTING
HOLES
COVER
BRAKE
SHAFT
Use approved safety procedures
WARNING
OIL
LEVEL
PLUG
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
AXLE
SUPPORT
CASE
AXLE
DOWEL
GASKET
2
. Axle supports, pressed from the inside out, must
be removed from the case and cover, similar to the
method used in the 1200 series transaxle.
GENERAL
The 1300 series unit, is driven by a hydrostatic pump
connected to the units case. The transmission function
is accomplished by the hydrostatic controls.The
Tecumseh/Peerless unit, therefore, only reduces input
shaft speed to the differential and axle assembly.
REMOVE MOUNTING
SCREWS (4)
INPUT
1
2
3
4
4
2
6
7
9
4
HYDROSTATIC UNIT
5
1
8
3
. To separate the hydrostatic unit from the 1300,
support both parts, then remove the four mounting
screws, and separate the parts. Drain the oil from
the 1300 unit. Any hydrostatic repair must be done
through the equipment brand dealer.
10
14
1
3
11
12
Legend for the 1300
1
2
3
4
5
6
7
- Oil Seal
8 - Axle
- Thrust Washer
- Brakeshaft
- Needle Bearing
- Output Gear
- Output Shaft
- Spacer
9 - Axle Support
10 - Bushing
11 - Cover
INPUT GEAR (DRIVEN)
12 - Differential Gear
13 - Case
14 - Thrust Washer
DISASSEMBLY
1
. Clean the exterior surfaces. Drain lubricant; then
separate the gear reduction from the hydrostatic
unit. Check axle shafts for rough edges and high
spots. Due to the hardness of the shafts, a stone
may be necessary to remove metal burrs. Check
for any evidence of oil leakage at the gasket or
bearing surfaces.
HYDROSTATIC UNIT
MOUNTING HOLES
4
. After removing the hydrostatic unit, inspect the
surfaces and the gears from outside the unit.
75
REASSEMBLY
5
. Remove the lockscrews and tap the dowel pins
out of the cover. Lift off the cover and discard the
gasket.
1
. When installing axle supports, be sure the case
and cover alignment is true with the press. Press
supports in until the flanged surfaces contact the
case and cover.
6. Lift out the brake shaft, gear, and thrust washers
on each side of the gears.
7
. Lift the output shaft, gear, spacer, and thrust washer
from the case. At the same time, lift out the differential
assembly.
2
. Install the differential and output shaft
simultaneously. Position the 3/4'’ (19.1 mm) I.D.
gear spacer and thrust washer on the shaft.
NOTE
3
. Center one 3/4'’ (19.1 mm) I.D. thrust washer over
the case needle bearings then install the brakeshaft
gear, and another 1-1/8'’ (28.6 mm) I.D. thrust
washer.
No thrust washer is located between the output shaft
and the case.
8
9
1
. To service the differential, refer to Chapter 18 on
differentials.
4. Position a new gasket on the mounting surface of
the case, then install the cover. Align the cover
and case by tapping dowel pins into the cover
and secure with lockscrews torqued to 10 ft. lbs.
. To service bearings, refer to Chapter 22 on bearing
service.
(
13.6 mm).
0. To separate axle supports from the case and cover,
use an arbor or hydraulic press. A piece of bar
stock should be used to protect the support from
the ram of the press that you are using.
5
6
7
. Install a new brakeshaft oil seal and axle using
seal protector.
. Install new axle support oil seals using a seal
protector.
INSPECTION AND REPAIR
1
. Inspect the case and cover for cracks, stripped
threads, marred sealing surfaces, and bearing
condition. The cause of any oil leakage should be
corrected and if parts cannot be repaired, replace
them.
. Add 2-3/4 pints (44 oz.) (1301 ml) Oil (S.A.E. EP
9
1
0) before securing the hydrostatic drive to the
300 series unit. Clean the mounting surfaces and
use a new gasket between the units. Torque the
four mounting bolts to 90-100 inch pounds (10.2-
11.3 Nm).
2
. Check shafts and gears for worn or chipped teeth.
Check bearing surfaces for scratches which might
affect oil seal performance. Check for wear.
3
. Check needle bearings and be sure the bearings
are not corroded or rusty. Replace bearings if in a
questionable condition. Check the quality of the
seal around the needle bearings.
4
. Check differential for rigidity. Wobble indicates wear.
Refer to the Chapter on differentials for service.
76
1300 SERIES HYDROSTATIC GEAR REDUCTION
DIFFERENTIAL
Oil Bath
S.A.E. E.P. 90 oil
Part No. 730229B
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
77
CHAPTER 14. 2300 SERIES FOUR-SPEED TRANSAXLES
H-SHIFT PATTERN
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
WARNING
INTERNAL QUAD
RING SEAL USED
AT THIS POINT
ROLL OR
DOWEL PIN
When shifting gears verify the
WARNING
3 SOCKET HEAD Cap
screws (TORQUE TO 10
FT. LBS. [13.6 Nm])
clutch is operated. Failure to do
so may cause premature transmission failure which
could result in death or serious injury.
GASKET
DO NOT shift on a hill or when
WARNING
INPUT
SHAFT
carrying a heavy load. Shifting on
a hill may cause premature transmission failure
which could result in death or serious injury.
DISASSEMBLY
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
CASE
We caution you against the use
WARNING
of aftermarket variations of braking
systems, adjustments and service of these
components. Removing or altering factory installed
parts my affect performance and could result in
death or serious injury.
SHIFTING
FORKS IN
NEUTRAL
COVER
•
Servicing the braking system will void your
warranty. See your Authorized Tecumseh
Servicing Dealer.
1
. Position the shifter forks in neutral before
disassembly.
GENERAL
SCRIBE MARK
IF NECESSARY)
AXLE HOUSING
The 2300 series transaxle is a four speed forward with
one speed reverse transaxle.
(
BRAKE SHAFT
MOUNTING BOLTS
COVER
SHIFT LEVER
AXLE
SHIFT LEVER
HOUSING
INPUT SHAFT
CASE
AXLE
HOUSING
I.D. TAG
2
3
. Remove both axle housings, and use the exposed
axle as a ram to separate the seal retainers from
the case and cover.
MOUNTING PADS
. When disassembling the rest of the unit, it should
be held so that it lies on the cover, properly blocked
up, so that no weight rests on the brake shaft. The
cover should sit rigidly so that the removal of parts
can be done in a systematic step by step procedure.
Be sure it does not fall causing injury.
78
4
. Oil seals are of the double lip type so sleeve
protectors do not offer much protection when
removing them. Upon replacement, new seals should
be used.
AXLE
INPUT SHAFT
BE SURE SEAL
IS REMOVED
1/32" (.794 mm)
THRUST WASHER
CASE
BRAKE SHAFT
3-GEAR CLUSTER
COVER
(8)
SOCKET
HEAD CAP
SCREWS
7
. Remove thrust washer and three gear cluster from
the brake shaft, noting whether the cluster has a
sloppy fit.
DOWEL PIN
5
. Tap dowel pins into the cover and remove the socket
NOTE
head cap screws.
To service the cluster bushings, refer to Chapter 22
on bearing and bushing service.
AXLE
8
. Inspect gear teeth for wearing, chipping or breaks.
Wear or chipping on the bevel area only, indicates
shifting while the equipment is in motion.
INPUT SHAFT
CASE
0
4
-1/2" TO 2"
5
1
(
TURN CW
COVER
38 - 50.8 mm)
6
. To separate the case from the cover. Lift the case
1
-1/2 to 2'’ (38-50.8 mm) above the cover. Tilt the
case so that the shift rods will clear the edge. Rotate
the case so the boss hidden inside will clear the
gears, then lift it free of the differential.
REVERSE IDLER GEAR AND SHAFT
9
. Remove the reverse idler gear, spacer and shaft
from the boss in the cover. Note that the spacer
goes between the gear and the cover, and the gear
bevels go down. Excessive wear on teeth bevels
indicates improper shifting technique.
79
1/32" (.794 mm) THICK 1" (19 mm)
I.D. THRUST WASHER IDLER GEAR
SHIFTING
ASSEMBLY
SPUR GEAR
LOW GEAR SPUR
BRAKE SHAFT
IDLER GEAR CHAMFERED SIDE
UP, AWAY FROM BEARING
1
0. Lift out the shifter assembly. Service of this unit is
described in Chapter 21 on shifting assemblies. If
it is evident that the shifter assembly needs no
further teardown, place it aside intact in a clean
place for servicing at a later time.
1
5. Remove the brake shaft.
NOTE
The brake shaft idler separates from the shaft. If
separated, be sure that when reassembled, the idler
gear chamfers are away from the cover.
1
1. Remove the low gear and shaft, and splined spur
gear. Separate the gear and shaft. Note there is
no thrust washer between the gear and case.
FOUR HEX BOLTS
HEADS UP
LOW GEAR
SHAFT BEARING
OUTPUT GEAR
AND SHAFT
DIFFERENTIAL
CARRIER
BEARING
BRAKE SHAFT BEARING
1/32" (.794 mm) THICK
LOW GEAR SHAFT
BEARING
3
/4" (19 mm) I.D.
THRUST
WASHER
BETWEEN
GEAR AND
BEARING
AXLE AND
DIFFERENTIAL
ASSEMBLY
SPACER
-GEAR CLUSTER
OUTPUT SHAFT
BEARING
2
BRAKE SHAFT
INPUT SHAFT AND GEAR
FLAT SIDE OF GEAR UP)
SHIFT LEVER OPENING
SHIFTER ROD SOCKETS
12. Remove the two gear cluster and spacer from the
brake shaft.
(
1
3. Lift the differential unit out of the cover.
*OUTPUT SHAFT
BEARING
*
SHIFTER SHAFT BEARING
NOTE
SHIFTER ROD SOCKETS
Service information appears in Chapter 18 on
differentials.
1
/16" (1.58 mm) THICK
5/16" (23.8 mm) I.D.
1
THRUST WASHER
*BRAKE SHAFT BEARING
REVERSE
IDLER
SHAFT
LOW GEAR
SHAFT BEARING
MAGNETIC
DRAIN PLUG
BOSS
DIFFERENTIAL
AND AXLE
ASSEMBLY
REMOVED
*BEARING TO BE .015" - .020" (.381-.508 mm)
BELOW THRUST SURFACE
OUTPUT GEAR
AND SHAFT
16. Remove the input shaft from the case by tapping
with a non-metallic hammer.
1
4. Remove the output shaft and gear and thrust washer
from each end of the shaft.
80
INSPECTION AND REPAIR
ASSEMBLY
1
/32" (.794mm) THICK
1
. Gears.
BRAKE SHAFT BEARING
LOW GEAR SHAFT BEARING
3/4" (19mm) I.D.
THRUST WASHER
BETWEEN GEAR AND
BEARING
a. Check bevels for evidence of damage due to
improper shifting.
DIFFERENTIAL
CARRIER
BEARING
NOTE
Input power to Tecumseh/Peerless Transaxles must
be stopped before shifting.
b. Check face of teeth for wear. Large shiny areas
indicate too much tooth contact and possible
excessive wear. Replace gears that are damaged
or show excessive wear.
LOW GEAR
SHAFT
BEARING
2
. Shafts and Axles.
INPUT SHAFT AND
GEAR (FLAT SIDE
OF GEAR UP)
SHIFTER ROD
SOCKETS
a. Check surfaces for rust, pitting, scratches or
wear.
SHIFT LEVER
OPENING
b. Check keyways, splines, threads, and grooves
for wear. Replace parts if worn or damaged beyond
a refinished state.
1. Install the input shaft in the case. Use a soft mallet
to seat the shaft and gear completely. Often, binding
in the assembled unit can be traced to a partially
installed input shaft.
3
. Case and Cover.
1
/32" (.794 mm) THICK, 1" (25.4 mm)
Check for cracks, stripped threads, metal chips,
flat sealing surfaces and rust. Clean out any rust.
Replace parts if any damage is found that cannot
be repaired.
I.D. THRUST WASHER UNDER IDLER
GEAR
4. Thrust Washers and Spacers.
Check for shiny surfaces which indicate wear and
replace if evident. Try to determine the cause of
thrust washer wear such as lack of end play due to
the reuse of an old gasket, or use of the wrong
thrust washer.
5
6
7
. Shifting Assembly.
Refer to Chapter 21on shifting assemblies.
. Gaskets.
BRAKE SHAFT
IDLER GEAR CHAMFERED SIDE UP,
AWAY FROM BEARING
2
. Center one 1/32'’ (794 mm) thick by 1'’ (25.4 mm)
I.D. thrust washer on the cover brake shaft needle
bearing, then install the brake shaft and gear, (with
the chamfer side away from the cover).
Replace all gaskets.
. Oil Seals.
It is a good habit to replace all seals. It is necessary
to replace all double lip seals. See Chapter 1, for
the paragraph on “OIL LEAKS, SEAL AND GASKET
SERVICE”.
1/16" (1.59 mm) THICK, 15/16" (23.8 mm) I.D.
THRUST WASHER
8. Bearings and Bushings.
Refer to Chapter 22 on bearings and bushings.
OUTPUT SHAFT
AND GEAR
OUTPUT SHAFT BEARING
3
. Install the output shaft and gear after centering a
/16" (1.59) thick by 15/16" (23.8 mm) I.D. thrust
washer on each end of the shaft.
1
81
AXLE AND
DIFFERENTIAL OUTPUT GEAR
FOUR HEX
BOLTS HEADS
UP
ASSEMBLY
AND SHAFT
BEVELED EDGE
LOW GEAR
SHAFT
BEARING
SPACER
2-GEAR CLUSTER
9
. Install the reverse idler shaft, spacer and gear into
the cover. The beveled side of the idler gear should
be down into the cover.
BRAKE SHAFT
4
. Insert the differential assembly into the cover. Note
that the four bolt heads should be facing away from
the output gear.
BRAKE SHAFT
5. Install the two gear cluster and spacer on the brake
shaft.
1/32" (.794 mm) THICK,
7/8" (19 mm) I.D. THRUST
WASHER IN PLACE ON
BEARING
REVERSE
IDLER
SHAFT
SQUEEZE SHIFTER
RODS TO HOLD
SHIFTER ASSEMBLY
TOGETHER
1/32" (.794 mm)
THRUST WASHER
3-GEAR CLUSTER
TWO GEAR
CLUSTER
AND SPACER
1
0. With the small gear of the three gear cluster toward
the spacer, install the three gear cluster and another
1
/32'’ (.794 mm) thick by 7/8'’ (19 mm) I.D. thrust
washer on the brake shaft.
AXLE
INPUT SHAFT
CASE
LOW GEAR
SHAFT
(
B)
SPUR GEAR
0
5
4
TURN CW
1-1/2" to 2"
38-51 mm)
(
6
. Install a 1/16'’ (1.59 mm) thick by 3/4'’ (19 mm)
I.D. thrust washer, gear and low gear idler shaft in
the cover. Do not put a thrust washer on the exposed
end of this shaft. Be sure the small gear meshes
with the larger gear of the two gear cluster.
COVER
7. Center one 1/32'’ (.794 mm) thick by 7/8'’ (19 mm)
I.D. thrust washer on cover shifter shaft bearing.
1
1. Position the gasket on the cover sealing surface,
then install the case over the differential shaft. Be
sure the boss goes under the gears and the edge
of the case goes over the shaft rods in the opposite
manner from which it was removed.
8. Install the shifter assembly (as a unit) into the cover.
82
1
2. Once in position, if the case hangs up 1/2" to 1'’
16. Upon installation of the axle housing, be sure
mounting pads face in the same direction as when
removed. Install cap screws and torque to 13 ft.
lbs.(17.6 Nm).
(
12.7 - 25.4 mm) above the cover, turn the input
shaft to get the gears to mesh. The case should
drop to about 1/4'’ (6.3 mm) from closing.
17. Install the shift lever housing and new gasket.
CASE
INTERNAL QUAD
RING SEAL USED
AT THIS POINT
ROLL OR
DOWEL PIN
3 SOCKET HEAD CAP
SCREWS (TORQUE TO
SHIFTING
FORKS IN
10 FT. LBS. [13.6 Nm])
NEUTRAL
COVER
INPUT
SHAFT
GASKET
1
3. Use a pair of needle nose pliers on the shifter stop
on each shifter fork to agitate the shifter rod ends
into their machined recesses in the case.
TESTING AND LUBRICATION
. For testing, refer to Chapter 1, page 6.
1
4. Align the case and cover with the two dowel pins,
then install and tighten the eight socket head cap
screws. Torque screws to 10 ft. lbs. Unit can now
be placed flat on the work bench.
1
2. For proper lubrication type and amount, refer to
Chapter 1.
NOTE
Seal protectors must be used, when installing a seal
over the axle ends or any shaft with a machined keyway.
OIL SEAL PROTECTOR
(USE DURING ASSEMBLY)
AXLE
OIL SEAL
BRAKE SHAFT
OIL SEAL
RETAINER
"O" RING
THRUST BEARING ASSEMBLY
1
5. Install new “O” rings and oil seals using the seal
protector as shown.
NOTE
Coating both the "O" ring and seal with lubricant will
help ease assembly.
83
2300 SERIES TRANSAXLES
LUBRICATION
Oil Bath
4 oz. (1892 ml) S.A.E. E.P. 90 oil
6
to be filled through shift lever opening
Part No. 730229B
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
84
CHAPTER 15. 2400 SERIES HYDRO POWERED TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
3. After the coupling is installed over the driveshaft of
the hydrostatic pump press the parts together.
Secure the assembly with three socket head cap
screws, torqued to the standard for the bolt being
used.
WARNING
Use approved safety procedures
VEHICLE MOUNTING HOLES
HYDROSTATIC UNIT
MOUNTING HOLES
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
COVER
BRAKE SHAFT
(RIGHT SIDE HERE)
INPUT SHAFT
(LEFT SIDE HERE)
AXLE SUPPORT
RETAINING BOLTS
The 2400 Series transaxle is a gear reduction unit
which is powered by a hydrostatic pump.
LONG AXLE SUPPORT
CASE
SEPARATING AND COMBINING THE HYDROSTATIC
PUMP AND THE 2400 SERIES TRANSAXLE.
SHORT AXLE
SUPPORT
HYDROSTATIC UNIT
MOUNTING HOLE
The two parts, gear reduction unit and pump, should
be removed from the vehicle together.
PRIOR TO REMOVAL, NOTE POSITION OF MOUNTING PAD IN RELATION TO
UNIT. (ALSO NOTE SIDE TO WHICH SHORT SUPPORT AND LONG SUPPORT
ATTACH).
DISASSEMBLY
4. Clean axles of burrs, rust and sharp edges.
5. Remove axle supports. Be sure to note in what
position and to which side they attach.
6. Drain the oil from unit. Remove the seal retainers
and “O” rings.
7
. Remove the eight socket head cap screws securing
the case to the cover. Drive dowel pins out of case
into cover, then lift case off of the cover.
MOUNTING SCREWS (3)
1
. To separate the units, block the assembly in a
protective vise, then remove the three hydrostatic
mounting screws. Separate one unit from the other.
If any binding occurs, remember that the drive shafts
are held in common rotation by a splined coupling
which will bind if the relationship between the input
shaft and the pump is not straight.
DIFFERENTIAL UNIT
(NOTE POSITION OF
CAP SCREW HEAD.
REASSEMBLE IN
COVER SAME WAY).
DIFFERENTIAL DRIVE
PINION AND GEAR
(OUTPUT)
COAT INSIDE OF COLLAR
WITH E.P. LITHIUM GREASE
MOUNTING SCREWS (3)
DOWEL PIN
COVER
INPUT
SHAFT
DRAIN PLUG
BRAKE SHAFT
AND GEAR
NOTE
FILL LEVEL PLUG
For service to the hydrostatic pump, it must be returned
to the dealer who sold the vehicle for his service
arrangement.
DOWEL PIN
8. Before removing the differential unit, note the position
of the cap screw heads. Replace the unit in the
same way to insure axle lengths will be correct
when installing the axle supports.
2
. To combine the hydrostatic pump and the 2400
transaxle, coat the splined coupling with E.P. Lithium
grease, and install it on the 2400 input driveshaft.
85
OUTPUT PINION,
GEAR AND
THRUST
INPUT SHAFT, GEAR AND
THRUST WASHERS
OUTPUT SHAFT
BRAKE SHAFT
WASHERS
BRAKE SHAFT
GEAR, SHAFT
AND THRUST
WASHERS
SPACER
INPUT SHAFT
COVER
9. Remove the input shaft and gear assembly. Note
that thrust washers are on both ends of the shaft.
1
0. Remove the output pinion and the gear splined to
it. Note the position of thrust washers on each
end of the pinion.
1
1. To remove the brake shaft, the shaft must be tapped
from the gear splined to it. Use a soft hammer.
Note that both ends of the shaft have thrust washers.
INSPECTION AND REPAIR
1. Clean all parts and examine for wear or damage.
2
. Refer to Chapter 18 on differentials for service when
working on differentials. Refer to Chapter 22 on
bearing and bushing service to replace any loose
or worn bearings.
3
. Remove and discard oil seals from the input and
brake shafts. Check axle seals and replace if any
evidence of leaking exists. If protective seal sleeves
were not used when removing seals and retainer
assemblies, replace seals after assembly. Use seal
protectors and correct drivers. See the paragraph
in Chapter 1 “OIL LEAKS, SEAL AND GASKET
SERVICE” for service.
4
. Install the differential unit with cap screw facing
down.
5. Position a new gasket on slightly raised dowels
and install the case. Turn down eight (8) socket
head cap screws lightly. Tap dowel pins in and
tighten the cap screws to 10 ft. lbs. (13.6 Nm).
6
. Use a seal protector and install the seal and retainer
assemblies. Position a new “O” ring on the seal
retainer. Be sure the mounting pad is in the correct
position. Install each axle support and bolt down.
Torque the cap screws to 13 ft. lbs. (13.7 Nm).
4. Clean the case and cover. Protect the bearings
from dirt. Lubricate the bearings to prevent rusting.
ASSEMBLY
1. Install thrust washer in the cover for input, output
7. Using the proper seal protector and driver, replace
the input and brake shaft seals.
and brake shafts.
2. Install the brake shaft into the gear in the cover.
8. Rotate shafts to check for binding or noise.
3
. Install the input and output shafts (with gear) and
position spacers on the brake shaft. Install thrust
washers on all shafts.
9. Add lubricant (2 pints [946 ml] S.A.E. EP90 oil) to
level of the fill plug with the unit in normal mounted
position.
CASE
COVER
THRUST WASHER
THRUST WASHER
SPLINED COUPLING
INPUT
SEAL
SEAL
BRAKE
THRUST WASHER
THRUST WASHER
OUTPUT
"
O" RING
NOTE POSITION OF
AXLE SUPPORT
SEAL RETAINER
NOTE POSITION OF CAP
SCREW HEADS
SEALED BALL
BEARING
NOTE, EQUAL LENGTH
AXLE EXTENSION FROM
EACH SUPPORT
SEAL
86
2400 SERIES HYDRO POWERED TRANSAXLES
LUBRICATION
Oil Bath
3
2 oz. (946 ml) S.A.E. E.P.
Part No. 730229B
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
87
CHAPTER 16. 2500 SERIES HYDRO POWERED TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
3. Clean all exterior surfaces of the transaxle.
WARNING
4
. Remove the axle supports. If supports are different
or if there is a chance for confused reassembly,
scribe alignment marks.
Use approved safety procedures
"O" RING SEAL
®
TIMKEN THRUST
ROLLER BEARING
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
GEAR REDUCTION AND DIFFERENTIAL UNIT
GENERAL
Most 2500 Series two speed gear boxes are run by
®
an Eaton Model 10 hydrostatic unit. Power for the
hydrostat is supplied by an engine with up to an 18
H.P. rating. The unit has infinite forward and reverse
speeds in both a high and low range. The 2500 series
are shipped without lubrication. Original equipment
manufacturers fill each gear case with lubricant when
installing the 2500 in the equipment. Lubrication for
the 2500 is 7 to 8 pts. (3.3 - 3.8 Lt) of SAE Type A
automatic transmission fluid.
5. Remove and discard square “O” ring seal.
6. If the tapered roller bearings are loose, remove them.
7
. Position the unit with the cover up side; then remove
the dowels and screws. Lift off the cover and discard
the gasket.
AXLE AND
DIFFERENTIAL
ASSEMBLY
WASHERS
THRUST OR
TABBED
OUTPUT SHAFT
AND GEAR
DISASSEMBLY
1. Remove piping and hydrostatic unit as necessary
to allow repair.
2
. Although the unit should have been drained of
lubrication, be aware that removal of the axle support
will allow trapped oil to spill.
HIGH
RANGE
DRIVEN
GEAR
NOTE
LOW
RANGE
DRIVEN
GEAR
An oil supply is blocked in the hydrostatic pump when
not running, so upon reassembly hydrostatic charging
is not necessary.
BOLT HEADS AWAY
FROM LARGE GEAR
SHIFT ROD
SNAP RING
NOTE
FORK
LOW RANGE DRIVEN GEAR
Any attempt to service the hydrostatic pump should
be done only upon authorization of Eaton or the
equipment manufacturer. Tecumseh does not authorize
repair or adjustment of the unit.
HIGH RANGE DRIVEN GEAR
8
. To remove the inside components, first remove the
INPUT DRIVEN BEVEL GEAR
DOWEL
differential and then thrust washers.
AXLE
SUPPORT
DOWEL
88
Case and Cover
FORK
SPRING
SETSCREW
1. Check for leaks or cracks.
2. As necessary, replace needle bearings as described
in Chapter 10.
DETENT BALL, SPRING
AND SETSCREW
3
. Do not replace brake shaft and shifter rod seals
SNAP RINGS
until the unit is reassembled.
DETENT BALL
BRAKESHAFT
HIGH RANGE
BEVELED SIDE
OF GEAR TEETH
BEVELED SIDE OF
GEAR TEETH
LOW RANGE
THRUST SPACER
SHIFTER AND
BRAKE SHAFT
OUTPUT
PINION
RETAINING
RING
THRUST OR
TABBED
WASHER
SHIFTER
FORK
HIGH
RANGE
GROOVE
LOW
RANGE
GROOVE
9
. To remove the shifter rod and fork, the set screw,
spring and detent ball should be removed from the
outside of the case.
SNAP RINGS (2)
SHIFTER ROD
NEUTRAL
GROOVE
Shafts and Gears
1. Check teeth for wear, pitting or breakage.
INPUT
SHAFT
THRUST WASHERS
SPACER
HIGH RANGE
TRANSMISSION
GEAR
INPUT
BEVEL
GEAR
(Shown
Assembled)
2
3
4
. Inspect bearing surfaces for smoothness.
BEVELED
ROUNDED)
SIDES
(
. Inspect gears and shafts for out-of-round.
. Splines should allow a smooth fit. Rotate meshing
parts for a better fit if binding seems excessive.
THRUST OR
TABBED
WASHER
THRUST
BEARING
SPACER
SHIFTER FORK
(PARTIALLY REMOVED)
LOW RANGE TRANSMISSION GEAR
FORK NORMAL
POSITION
HIGH RANGE
GROOVE
INPUT
SHAFT
1
0. Remove both the input and shifter gear and shaft
assemblies, along with the shifter rod and fork.
LOW
RANGE
GROOVE
SNAP RINGS
(SHARP SIDE OUT)
11. Remove the input shaft and gear assembly.
NEUTRAL
12. Remove the output shaft and gear.
INSPECTION AND REPAIR
Shifter Mechanism
. Check spring for tension and ball for wear.
Axle Supports
1
1
. Check ball bearings and bearing races for wear,
rust and ease of rotation. Clean the interior of the
support if necessary.
2. Check shifter rod grooves for wear. Be sure the
sharp edge of the snap ring goes away from shifter
fork.
2
. Replace the oil seals in the axle supports.
. Check for cracks in the support.
3. Inspect the shifter fork for straightness and wear.
3
89
Differential
ASSEMBLY
Install parts reversing the disassembly procedure. Be
careful of the following:
SETSCREW
FORK
SPRING
DETENT BALL, SPRING
DETENT BALL
AND SETSCREW
SNAP RINGS
AXLE AND
DIFFERENTIAL
ASSEMBLY
BRAKESHAFT
PINION
RETAINING RING
CORE BODY
1
. After the shifter rod is positioned, install the detent
ball, spring and setscrew. Slowly turn the setscrew
inward while raising and lowering the rod until the
detent ball stops the rod movement.
AXLE
AXLE
DRIVE
GEAR
2. Be sure that thrust washers and spacers are between
every shaft and the case and cover.
LIMITED
SLIP DIFFERENTIAL
3
. Threads of the differential bolts must be coated
with standard stud Loctite. The bolt heads on the
differential are up when installed.
1
. Make sure you have all parts are present.
4
5
6
. Install a new gasket. It may be helpful to dampen
the gasket with oil to get it to lie flat.
2. Check the snap rings for their condition.
. Use a seal protector to protect the axle support oil
seals during installation.
THRUST WASHER
. Install axle supports correctly. Do not rotate the
support to a new position when pressed tight against
the square “O” ring seal or the seal may be cut.
COUNTER RETAINER
BORE FOR RING
AXLE
DRIVE
AFTER ASSEMBLY
GEAR
AXLE
(SPLINED
END)
1
2
3
. To install the brake shaft oil seal using a seal
protector.
. To install the shifter rod oil seal, use seal sleeve
670206 and driver 670211.
. Lubrication for all models is 7 to 8 pints (3.3 - 3.8
Lt) of S.A.E. Type A automatic transmission fluid.
When filling, allow the fluid to settle behind the
tapered bearings into the axle supports. This may
necessitate filling, checking and adding. The oil
fill hole is located in the case. If the shrouding on
the equipment does not allow access to the oil fill
hole when the 2500 is installed in the chassis,
lubrication should be filled prior to installation in
the equipment. If filling takes place before installing
RETAINING RING
Other
1. Check thrust washers for wear.
2. Check tapered roller bearings for wear and ease of
rotation.
o
the 2500, orient the unit to a 90 angle to the axles.
There should be no fluid leak.
3. Replace the shifter rod oil seal after assembly of
all parts.
4. Install the drive assembly according to the
manufacturer’s instructions.
4. Check thrust bearing for wear. Replace any parts
necessary.
90
LOW RANGE TRANSMISSION
DRIVE GEAR
HYDROSTATIC DRIVE
MOUNTING SURFACE
DRIVEN
INPUT
GEAR
HIGH RANGE TRANSMISSION
DRIVE GEAR
SPACER
THRUST BEARING
SPACER OR SHOULDER
INPUT SHAFT
THRUST WASHER
TABBED THRUST WASHER
SHIFTER AND BRAKE SHAFT
OIL SEAL
BEVELED SIDES OF GEARS
OUTPUT SHAFT
TABBED THRUST
WASHER
TABBED THRUST
WASHER
THRUST
WASHER
THRUST
WASHER
SEAL
BALL BEARINGS (2)
"O" RING SEAL
ROLLER BEARINGS (2)
NOTE: NO BEARING AT THESE POINTS
NEEDLE BEARINGS (2)
91
2500 SERIES TRANSAXLES
LUBRICATION
Part No. 730229B
Refer to O.E.M. manual for
type of lubrication.
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
92
CHAPTER 17. 2600 SERIES HYDRO POWERED TRANSAXLES
It is recommended that you take
special notice of all items
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
5. To remove axle out of its support, tap lightly with a
mallet from the inside out. A pressed-on sealed
bearing will be on the end of axle.
WARNING
6
. Position the unit with the cover side up. Then remove
the dowels and screws. Lift the cover off, and discard
the gasket.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
DIFFERENTIAL
INPUT SHAFT
SHIFTER SHAFT
SHIFTER GEAR
CLUSTER
GENERAL
The 2600 series transaxle has infinite forward and®
reverse speeds. It is powered by a Sundstrand
hydrostatic drive connected to an engine with up to a
OUTPUT SHAFT
Dual Range with Lock Differential
2
0 Horsepower rating. The 2600 series are shipped
INPUT SHAFT
DIFFERENTIAL
without lubrication from Tecumseh/Peerless. Original
equipment manufacturers fill each gear case with
lubricant when installing the 2600 in the equipment.
Lubrication for the 2600 is 7 to 8 pts. (3.3 - 3.8 Lt)
SAE Type A automatic transmission fluid.
COUNTER
SHAFT
DISASSEMBLY
1
. Remove the hydrostatic pump as necessary to allow
OUTPUT SHAFT
repair.
Single Range without Lock Differential
NOTE
There are two different 2600 models as shown
above.
An oil supply is blocked in the hydrostatic pump when
not running so upon reassembly, hydrostatic charging
is not necessary.
SPACER
THRUST
BEARING
2
. Although the unit should have been drained of
lubrication, be aware that upon removal of the axle
support, the axle will be removed as well. This will
allow trapped oil to spill.
NOTE
Any attempt to service the hydrostatic pump will be
®
done only upon the authorization of Sundstrand or
the equipment manufacturer. Tecumseh does not
authorize repair or adjustments.
THRUST
WASHERS
INPUT SHAFT
3. Clean all exterior surfaces before disassembly.
4. Scribe alignment marks on the unit before removal
to assist in reassembly. Remove the axle supports.
ALIGNMENT SLEEVES
WILL BE PRESENT
BETWEEN AXLE
COUNTER SHAFT
SUPPORT AND UNIT
7
. To remove components from the single speed version,
first remove the differential, thrust washers, drive
gear, input shaft, countershaft, output gear and
shaft.
I.D. TAG
93
8
. To remove components from the 2 speed with locking
differential version, remove the shifter rod and fork,
the outside bolt, spring and detent ball. Next remove
the high range gear; then the shifter gear cluster
and fork assembly together.
4. Splines should allow a smooth fit. Rotate meshing
parts for a better fit if binding seems excessive.
Shifter Mechanism (Dual Range).
BOLT, SPRING AND BALL
DIFFERENTIAL LOCK
FORK ASSEMBLY
HI-LOW SHIFT
FORK AND
ROD
1. Check spring for tension and ball for wear.
2
. Check shifter rod grooves for wear. Be sure snap
ring sharp edges goes away from shifter fork on
both shifter shafts.
9
. Remove the input shaft assembly.
HIGH RANGE GEAR
THRUST WASHERS
3. Inspect shifter fork for straightness and wear.
Differential
1
. Make sure you have all parts.
. Check thrust washers for wear.
2
THRUST BEARING
SPACER
LOW RANGE
GEAR
INPUT SHAFT
LOCK COLLAR AND PIN ASSY.
BALL BEARING
1
0. Remove shifter shaft, output shaft and the output
gear in this order.
11. Remove differential and lock fork assembly together.
INSPECTION AND REPAIR
Axle Supports.
LOCK DIFFERENTIAL
NON-LOCK DIFFERENTIAL
1. Check the roller bearings on the axles. Clean and
remove any rust.
3
. Check differential lock collar for fork or pin wear.
2
. Clean the axle supports and inspect.
4. Check ball bearings for ease of rotation. Replace
any parts if necessary.
Case and Cover.
ASSEMBLY
1. Check for leaks or cracks.
Install parts reversing the disassembly procedure. Be
careful of the following:
2
. Replace all oil seals. As necessary, replace needle
bearings as described in Chapter 22 on bearing
service.
1
. After the shifter rod is positioned, install the detent
ball, spring and bolt. Turn the set bolt inward (dual
speed) until it contacts the case.
3
. Do not replace brake shaft seal, brake shaft, shifter
rod and shifter differential lock seals until the unit
is reassembled.
2. Be sure that thrust washers and spacers are between
every shaft and case and cover.
Shafts and Gears.
1. Check teeth for wear, pitting or breakage.
2. Inspect bearing surfaces for smoothness.
3. Inspect gears and shafts for an out-of-round condition.
3. Threads of the differential bolts must be coated
with standard stud Loctite. The bolt heads are up
when installed. Refer to Chaper 18 on differentials.
4
. Install a new gasket. It may be helpful to dampen
the gasket with oil for easier installation.
94
5
. To place axle assemblies into case and/or cover,
grease axle spline ends heavily. Push the axle
through the seal, using extreme caution when axle
splines are going through the seal.
NOTE
If you do not have the proper seal protector spray axle
with brake cleaner and when dry, place one layer of
thin, clear packing tape around splines and keyways.
Lubricate the exposed tape, and the seals will be
protected when pushing the axles through.
6
7
8
9
. After the unit is assembled install the brake shaft
oil seal, using a seal protector/installer.
. Install the shifter rod oil seal, using the seal protector
670206 and driver 670211.
. Install the locking differential shifter rod oil seal,
using the seal protector 670206 and installer 670211.
. Lubrication for all models is 7 to 8 pints (3.3 - 3.8
Lt) of SAE Type A automatic transmission fluid.
95
2600 SERIES HYDRO POWERED TRANSAXLE
SINGLE SPEED
LUBRICATION
Part No. 730229B
Refer to O.E.M. manual for
type of lubrication.
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
96
2600 SERIES HYDRO POWERED TRANSAXLE
TWO SPEED
LUBRICATION
Part No. 730229B
Refer to O.E.M. manual for
type of lubrication.
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
97
CHAPTER 18. DIFFERENTIALS
It is recommended that you take
special notice of all items
WARNING
100 SERIES DIFFERENTIAL
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
SNAP
RING
HOUSING
AXLE
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
THRUST WASHER
PINION GEARS
HOUSING
DRIVE PIN
4
. Remove the snap ring, bevel gear and thrust washer.
GENERAL
Slide the axle from the differential carrier housing.
NOTE
The differential assemblies of Tecumseh/Peerless units
are grouped together in this section. Though there is
little similarity between the 100, 600, 800 and remaining
series units, they are grouped here because their
function is the same.
Bushings are replaceable in the differential carrier
housing. To replace bushing, use bushing tool 670204.
ASSEMBLY
1
. Slip the axle into the differential housing carrier.
Place the thrust washer and bevel gear on the axle
and secure with a snap ring. Make sure the flat
side of the snap ring is away from the gear.
The differential assemblies for the 820, 1200, 1300,
2
300 and 2400 series Peerless units are very similar.
However, each must be assembled in its own way. By
grouping them together, you will become more aware
of differences in each unit.
2. Place pinion gears and thrust washers on the drive
pin and insert the assembly into either differential
housing carrier.
MODEL 100 DIFFERENTIAL
DISASSEMBLY
3. Use 3 oz. (89 ml) of bentonite grease as a lubricant.
1
. Clean the outside of the differential. Remove all
keys, pins, etc. Remove all burrs from keyways
and holes. Use a stone on hardened shafts.
4. Assemble the differential carrier housings and
sprocket with 4 bolts and locknuts.
NOTE
AXLE
No oil seals or gaskets are required in this unit. A few
units use a gasket between the two housings and seals
around the axles.
HOUSING
If no gasket is present, seal the housing with Loctite
AXLE
5
98 part number 788093 using a 1/8" (3.18 mm) bead.
MODEL 600
DISASSEMBLY
SPROCKET
LOCK NUTS (4)
NOTE
2
. Remove four (4) locknuts, bolts and the sprocket.
Axles vary in length so make a sketch of which axle
goes where.
Separate the differential carrier housings.
DRIVE PIN
AXLE
AXLE
AXLE
AXLE
HOUSING
PINION
GEARS
BEVEL GEAR
ROLL PIN
DRIVE PIN
3
. Remove the drive pin, pinion gears and thrust
1. Drive out the roll pin that secures the drive pin with
a suitable punch.
washers as a unit.
98
3
. Install the bevel pinions SIMULTANEOUSLY FROM
OPPOSITE SIDES by rotating pinions in opposite
directions while sliding into position in gear
assembly. Check the alignment by inserting fingers
into drive pin holes. If not aligned, the drive pin
cannot be inserted. Remove and replace the bevel
pinions as only one tooth out of position will cause
misalignment.
DRIVE PIN
AXLE
BEVEL PINIONS
AXLE
BEVEL GEARS
AXLE
BEVEL GEARS
2. Remove the drive pin.
BEVEL PINIONS
BEVEL GEARS
AXLE
THRUST WASHERS
4
. After aligning, insert thrust washers behind each
pinion. Insert the drive pin and secure with a roll
pin.
MODEL 800
BEVEL PINIONS
DISASSEMBLY
THRUST WASHERS
1
. Same as disassembly for model 600, except for
additional parts on the axle.
3
. Thrust washers must be removed before attempting
to remove the pinions. Remove the bevel pinions
simultaneously by rotating the gears in the opposite
direction; the gears will move out of position.
2. Remove and inspect seals, bearings and washers
for wear; replace if necessary.
3
. If differential was disassembled note positioning
of differing length axles so correct reassembly may
be performed.
REASSEMBLY
1. Reassemble in reverse order of disassembly.
SNAP RING
CUP FACES
CUP FACES
OUT
OUT
SEAL
SEAL
4. Remove snap ring, bevel gear and thrust washer.
Slide the axle out.
BEARING
WASHERS
BEARING
5. Inspect the bushings and gears for wear and replace
when necessary.
REASSEMBLY OF DIFFERENTIAL ASSEMBLY
BEARING
NEEDLE TYPE)
BEARING
NEEDLE TYPE)
(
(
1. Place axles (left and right) into differential gear
assembly. Install thrust washers.
2
. Install seal cup end out from the center of the
2. Place the bevel gears on the shaft and install the
snap ring in the groove on the shaft.
differential to prevent dirt entry.
99
MST SERIES DIFFERENTIAL
OLD STYLE
A"
SQUARE CUT
O" RING
"
This unit is similar to the 900, except it uses no bearing
blocks. The differential is supported by the shoulders
on the ring gear.
"
"
C"
CAST IRON DIFFERENTIALS USED IN TECUMSEH/
PEERLESS TRANSAXLES
SEAL
NEW STYLE
RING GEAR
"
B"
DIFFERENTIAL
"D"
HEAVY DUTY SEALED
BALL BEARING
SEAL
BEARING SURFACE
HEX HEAD BOLT
The 800 Series has used four styles of axle bearings.
The earliest style “A” was a smaller loose cage needle
bearing and must have the seal to the outside of that
bearing. Style “B” must have the seal to the outside of
the bearing. When bearing style “C” is used, a square
cut “O” ring must be used on each side of the bearing.
Bearing style “D” is a sealed ball bearing used in Heavy
Duty applications. Styles “B”, “C” and “D” are
interchangeable. Needle bearings A, B, and C must
be repacked with E.P. Lithium grease.
NOTE
The models covered are the 820, 1200, 1300, 1700,
2000, 2300 and 2400 series.
The differential construction may vary from the
illustrations but is basically similar.
NOTE
FOUR RETAINING BOLTS
SNAP RING
RETAINER
Needle bearings are lubricated with E.P. grease. DO
NOT USE BENTONITE on needle bearings. For
maximum gear train life use only Bentonite grease on
all shafts and gears, Tecumseh part number 788067C.
8
6
4
5
1
7
2
3
MODELS 900, 910, 915, 920 and 930
DIFFERENTIAL
DIFFERENTIAL
CARRIER WITH
THREADED
PINION GEAR
DRIVE BLOCK
This style differential is supported by the case and
cover with thrust load being absorbed by either bearing
blocks or a bearing strap as shown. Both types use
thrust washers on the axle bevel gears.
BOLT HOLES
DIFFERENTIAL
GEAR
DRIVE PIN
DIFFERENTIAL ASSEMBLY
The 1200 series differential carrier is supported directly
on the axle (1). Roller thrust bearings (2) are used
between the bevel gear (3) and the differential carrier
BEARING STRAP
(
4). This illustration shows axles with snap ring (5)
DIFFERENTIAL
BULL GEAR
retainers; some earlier production had rolled over axle
ends to secure the assembly. Thrust washers (6) are
used at the ends of the differential carriers and the
case/cover thrust face. The drive pin (7) and drive blocks
(8) are similar to those used on the 1700 series. Replace
the differential carrier if worn in excess of .878 (22.3
mm) at point A.
BEARING BLOCKS
BEVEL
GEAR
AXLE
WASHER
2
SNAP RINGS
BEVEL PINIONS
RING GEAR
Ensure you have all of the parts as the unit is assembled
in your hands and placed directly into the case.
1
00
2
THRU BOLT HOLES
DRIVE PIN
RING GEAR
POINT Ab
1
3
DRIVE BLOCKS
TWO PINIONS
The 2000 series, three speed and the 2300 series,
four speed differential will be discussed in this section.
Examine the external bearing race on the differential
carriers (1) for wear or pitting. Replace if necessary.
The differential carriers in this assembly have
replaceable bushings (2). Replace if worn in excess
of .878" (22.3 mm) at point A. See Chapter 22 on
Bearing and Bushing Service. These differentials have
been built with rolled axle ends and also snap rings
5
. If a snap ring is used, the axle assembly may be
disassembled. If the axle end has been rolled, do
not attempt to break the rolled retaining edge. The
parts are to be replaced as an assembly.
SNAP RING
RING GEAR
AXLE END
(
3), as illustrated.
DISASSEMBLY
1
. Clean the differential assembly, then check and
note the axle lengths and their relation to the heads
of the four hex screw bolts.
THRUST
DRIVE BLOCK
2. If the unit will not turn freely, note where the unit
binds. Check and replace those parts.
WASHER
SEAT
FOUR HEX
HEAD
BOLTS
6
. Remove the snap ring and the thrust washer.
Separate the bevel gear and the differential carrier
from the axle.
RING GEAR
INSPECTION
1. See Chapter 22 on Bearing and Bushing Service.
BEARING RACE
2
. Examine the gears for wear, cracked or chipped
teeth. Check the internal splines of the gears and
axle if the gear is removable. If excess play is noted,
it may be necessary to replace the individual parts
or both the gear and axle.
DIFFERENTIAL
CARRIER
3
. Examine the drive pinions, drive pins and drive blocks
for wear and damage. Replace the pinion or the
drive pin if excessively worn.
3
. Place the differential in a large vise with soft jaws
(
hex head bolts up). Do not clamp the vise on the
bearing race of a differential carrier.
4
. Remove the four hex head bolts, the upper axle
and differential carrier. Remove the drive blocks,
pinions, drive pin and thrust spacer if used, by lifting
them out of the ring gear. Tap the ring gear lightly
with a mallet to loosen them from the differential
carrier.
101
TESTING
HOLES THREADED
IN ONLY ONE
DIFFERENTIAL
CARRIER
1
. Test the differential action by holding the upper
axle vertically, and spinning the differential. The
unit should spin and rotate freely. Place the
assembly on the bench and rotate both axles in
different directions. If any binding is noted in either
test, check retaining bolt torque, gear meshing, or
bearing surfaces in the differential carriers. Little
or no play should be apparent between the axles
and carriers.
SNAP RING
BEVEL GEAR
DIFFERENTIAL
CARRIER RING
GEAR REMOVED
THRUST
WASHER
DUO-TRAK (Illinois tool works)* DIFFERENTIAL
OPERATION
4
. Examine the differential carriers. One has threaded
holes and the other has larger holes so the bolts
will pass through. Be sure to order the correct
replacement parts.
A cylindrical spring in the center of the unit presses
the ten pinion gears against their pockets setting up
a resistance to rotation. This resistance serves to lock
up the gears in the differential until a moderate tractive
difference in the wheels causes the resistance to be
overcome. At this time the unit will act similar to a
regular differential. The break away occurs when the
equipment is turning, but under different tractive effort
situations, such as operation on wet grass or snow.
The spring acts to transmit torque to the non-tractive
wheel to move the equipment.
5. Examine the internal bearing diameter of the
differential carriers.
SERRATED AXLE END
DISASSEMBLY, INSPECTION AND REPAIR
Parts breakdown will be found on the next page. Remove
the four through-bolts. Separate axle assemblies from
the body cores. To disassemble the axles, remove
the snap ring and retained parts. Be sure the flanged
thrust washer goes toward hub end of the axle upon
ROLLER THRUST
DIFFERENTIAL
CARRIER
BEARING WITH
ONE THRUST
WASHER
o
reassembly. Use a pair of large 90 tip snap ring pliers
and remove the cylindrical spring putting tension on
the ten pinion gears. Once the spring is removed, the
gears can be removed. Separate the two body cores
from the ring gear.
6
. When assembling thrust bearings, always place a
hardened thrust washer on each side of the caged
thrust rollers. Never use the caged thrust rollers
without the thrust washers.
ASSEMBLY
Install the body cores to the ring gear so that the pockets
in one core are out of alignment with pockets in other
core. Reassemble the thrust washers, bearing, carrier
and side gear to the axle and secure with the snap
ring. Install the pinion gears on one side, then use the
differential carrier and axle to hold them from falling
out when the unit is turned over. The side gear must
mesh with the flat pinion. Install pinions in the other
side to mesh with the previously installed pinions. Insert
REASSEMBLY
1
. Oil all parts during reassembly. Select the correct
axle for the side of the differential opposite the
hex head bolts. If the wrong axle is used it will
require complete teardown of the differential, or
possibly the entire transaxle.
2
. Clamp the axle, in a soft jaw vise (not the bearing
or oil seal surfaces). The differential carrier with
threaded holes is assembled to this axle.
o
the cylindrical spring with a pair of large 90 tipped
snap ring pliers so that it bottoms on the side gear.
All ten pinions should be in contact with the spring.
Install the other axle and secure the assembly with
four through bolts and torque to 7-10 ft. lbs. (5.2 - 13.6
Nm).
3. Torque the four hex head bolts to 7 ft. lbs. (5.2
Nm).
1
02
BODY CORES
RING GEAR
PINION GEARS
SPRING
ONLY OLDER UNITS)
(
SNAP RING
®
DUO-TRAK "
"
®
DUO-TRAK is the trademark of a patented limited slip differential designed by Illinois Tool Works.
*
The Model 2600 transaxle has the unique customer option of a semi-locked differential. This system acts like
a locked differential until the torque at the axle exceeds 50-70 ft./lbs. (68 - 95.2 Nm). At this point it acts like a
regular differential. Using the following procedure, you can check for proper condition of this optional unit used
on a few 2600 models, but not on all units.
1
. Lift the rear of the tractor up so both tires are off the ground. Rotate one tire while in neutral; the other tire
should rotate in the same direction. If not, disassemble the unit. If it does proceed to step 2.
2. Lock one axle or wheel assembly so it can not turn.
3. Using a torque wrench and socket on the other axle, turn in a clockwise rotation noting the break away
point. It should be between 50-70 ft. lbs. (68 - 95.2 Nm).
4. If the torque is low, you will need to split the ring gear and carrier. Remove any shim between the two halves.
If you do not find a shim, you will need to replace the spacer block. (see Illustration)
5
. Re-assemble and check for proper break away torque as listed above. Breakaway should not exceed
7
0 ft./lbs (95.2 Nm).
BELLEVILLE WASHER
ORIENTATION
103
CHAPTER 19. DRIVES
This chapter relates to service of all Right Angle and T-drives.
It is recommended that you take
special notice of all items
WARNING
DRIVE BEVEL GEAR
SNAP RINGS
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
Use approved safety procedures
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
FINNED COVER
OUTPUT SHAFT
DRIVEN BEVEL GEAR
IN LOWER POSITION
3
. Output shafts achieve a different rotation by
mounting a gear at the top or bottom of the shaft.
GENERAL
1
. Prior to removing the assemblies, examine the
following items that may have failed causing the
right angle drives to appear inoperative.
1
/2" (12.7 mm) TO
/4" (19.1 mm)
MACHINE BOLT
APPROXIMATELY
3
DIAMETER BOLT
4" (10 cm) LONG
2
3
4
. Drive belts: Inspect for breaks, tension, oil or grease
OUTPUT
SHAFT BALL
BEARING
HEX NUT
saturation and inoperative tightening devices.
. Pulleys: Tighten retaining screws. Examine for
sheared keys.
LARGE WASHER TO
REST ON OUTER
BEARING
. Mower blade clutches and breakaway devices; some
blades have slip type clutches that may slip during
operation which may cause the right angle drives
to appear to be damaged. Shearing devices are
also used to absorb a damaging impact load. Check
and replace the clutch members or shearing devices
prior to removal of the right angle drive if a failure
is noted.
METAL PLATE TO
PROTECT LOWER
BEARING
INPUT SHAFT
BEVEL GEAR
4
. If the driven bevel gear is on the bottom, remove
the snap ring on the output shaft and pull out the
output shaft.
5. Loose blade retaining nuts; Check torque and
tighten if required.
5. Remove the output shaft bearing by using a large
machine bolt, washer and nut.
FINNED COVER RIGHT ANGLE DRIVE
When finned cover right angle drives are to be serviced
because of lubricant leakage, it will be necessary to
replace the ball bearings.
SNAP RING
OUTPUT SHAFT
AND BEARING
DISASSEMBLY
1. Scribe marks on the covers and shafts to ease in
reassembly.
2. Remove the cover, gasket and the lubricant from
the drive.
INPUT SHAFT
6
. The input shaft bearing, input shaft and bevel gear
may now be driven out of the housing. Press the
bearing into housing to remove.
7
. The top ball bearing in the blind end of the housing
is removed by heating the housing on a hot plate
and tapping the outside of the housing with a
nonmetallic mallet. Another option is to simply load
the bearing area with grease and tap the output
shaft in the center of the bearing quickly with a
hammer. It will pop the bearing out of its position.
1
04
NUT
WASHER
MOWER BLADE
APPLY SMALL
AMOUNT OF GREASE
BETWEEN NUT AND
MOUNTING SURFACE
Clockwise
LEFT HAND
8
. Right angle drives with the driven bevel gear at the
top will have to be disassembled as illustrated above.
The output shaft is larger in diameter inside than
outside. When the output shaft is pulled out, the
bearing will also be removed.
INSPECTION
Clockwise
Clean all parts in a cleaning solvent. Examine for wear
or damage and replace as needed. Use care when
handling ball bearings. See Chapter 22, Bearing and
Bushing Service.
Counter Clockwise
RIGHT HAND
REASSEMBLY
Assemble in reverse of the disassembly instructions.
It is important that only ball bearings with snap rings
be used for the input shaft and top output shaft bearing.
Use a tool for driving in bearings. In the event bearing
bore is tight in the housing, heat the housing on a hot
plate. Place a steel plate on the hot plate and rest the
housing on the steel plate. DO NOT OVERHEAT. Work
rapidly after removing the housing from the hot plate.
Use care to prevent burns.
Clockwise
LUBRICATION
See Lubrication Chart in Chapter 1.
Counter Clockwise
RIGHT HAND
Clockwise
LEFT HAND
Clockwise
RIGHT ANGLE DRIVE ROTATION
Clockwise
105
DISASSEMBLY
SMOOTH COVER RIGHT ANGLE DRIVE
1
. Scribe marks on the covers and shafts to aid in
reassembly.
BEARING AT INNER EDGE OF
MACHINED SURFACE
GASKET
SEAL
COVER
INPUT
SHAFT
BALL BEARING
2. Remove the cover, gasket and lubricant.
INPUT SHAFT
DRIVING BEVEL
GEAR
SERVICE
Leaking lubricant: Correct lubricant leakage by replacing
the seals at the input and output shaft as described
below.
1
. Input shaft seal replacement: Remove four screws
and the cover. Replace the seal by driving in squarely
so that it is .040'’ to .050'’ (1.02 - 1.27 mm) below
flush. Use tool 670293 to protect the seal when
replacing the cover and seal assembly over the
input shaft. Place the seal protector on the shaft
and coat with oil. Slide the seal and cover over the
sleeve. Tighten the seal retainer screws and remove
the sleeve.
SNAP RING
3. If the unit is built with the bevel gear on the input
shaft toward the cover, remove the snap ring from
the groove of the input shaft.
SHEET METAL
SCREW
OUTPUT SHAFT
HOLE IN SEAL
SNAP RING
OUTPUT SHAFT
SEAL
2
. Output shaft seal replacement. Remove the seal
by punching two small holes in the seal with an
awl as close to the outer edge of the seal as possible
and opposite each other. Use care when making
holes in the seal so ball bearing underneath is
not damaged. Do not use a drill. Insert sheet metal
screws into the holes and pull on the screws to
remove the seal. Long screws may be turned in
until they contact the outer race of the ball bearing
and turned to lift out the seal. Place seal protector
4
. Remove four screws and the cover/seal assembly.
. Remove the seal at the output shaft.
5
6. Remove the snap ring on the output shaft and tap
it with a mallet on the outside end to drive it and
the inner ball bearing out of the housing. Remove
the output end ball bearing by driving it out from
the inside.
6
70293 on the shaft, lubricate generously with oil
and slide on the seal. Drive the seal into the housing
until it is flush with the bottom of the housing.
1
06
“
T” DRIVE SERVICE
BEVEL GEAR
1
. Before removing a “T” Drive from equipment, be
sure to scribe marks at one mounting hole to ensure
correct reassembly.
OUTPUT SHAFT
"T" DRIVE WITH DIFFERENT INPUT AND
OUTPUT ENDS OF INPUT SHAFT
DRIVE MODEL
NUMBER
BALL BEARING
7
. Remove the input shaft from the ball bearing with
an arbor press. Always support the inner race when
removing and replacing the input shaft into the ball
bearing. Use tool 670293 to support the inside ball
bearing race.
"
T" DRIVE WITH IDENTICAL
INPUT AND OUTPUT ENDS
OF INPUT SHAFT
BLIND
BEARING
2. To disassemble “T” Drive, remove self-tapping screws
and housing cover and clean grease from internal
area. Note and mark near the gasket surface on
the side where the beveled input gear is located.
SNAP RING
DRIVEN BEVEL
GEAR ON OUTPUT
SHAFT
o
Switching the “T” 180 will result in the output shaft
having the opposite rotation.
WHEN THE INPUT END OF SHAFT IS ON THIS
END THE OPPOSITE END IS THE OUTPUT
BEARING CAP AND
SEAL RETAINER
INPUT SHAFT
8
. The ball bearing that supports the inside end of the
input shaft is removed by holding the housing in
hand while tapping the housing sharply on the outside
with a nonmetallic soft mallet behind the bearing.
It may be necessary to heat the housing to remove
this bearing. Be careful not to distort the case by
overheating.
HOUSING
OUTPUT
SHAFT BEVEL
GEAR
IF INPUT END OF
SHAFT OTHER END IS
OUTPUT END
INSPECTION
INPUT SHAFT
BEVEL GEAR
Clean all parts in a cleaning solvent. Examine for wear
or damage and replace parts as needed. Use care
when handling ball bearings. See Chapter 22 on Bearing
and Bushing Service.
3
. Remove cap screws and both retainer cap and seal
assemblies. Separate and discard oil seals and
gaskets.
REASSEMBLY
Assemble the unit in reverse of the disassembly. When
building up the unit, it is important to install the correct
input shaft and identify it with the correct cover. Use
the identifying scribe marks to assemble parts correctly.
BEARINGS ARE
SLIP FIT ON BOTH
INNER AND OUTER
RACES
LUBRICATION
See the Lubrication Chart in Chapter 1.
4
. Press input shaft ball bearings out of the housing
with fingers. If they stick, tap lightly using a drift
punch around the outer race.
107
9
. Press shaft, bearing and gear assembly into the
housing until outer bearing race bottoms in its
retaining cavity.
10. Install the outer bearing and a new snap ring.
USE THE PROPER
SIZE SEAL
PROTECTOR
HOLD GEAR WITH FINGERS,
THEN TAP ON END OF
SHAFT WITH MALLET TO
SEPARATE
ALWAYS REPLACE
OIL SEALS
5
. Using a soft mallet, separate the input shaft and
gear. A slight press fit holds a spline surface on
the shaft in a spline of the gear.
6
. Remove and discard the output shaft oil seal. TAKE
CARE NOT TO SCRATCH THE SHAFT. Remove
and discard the snap ring and tap the shaft into
the housing using a nonmetallic mallet.
11. Install a new oil seal, using a seal protector sleeve
part # 670293 and driver until the seal is flush with
the housing.
TO REMOVE GEAR
REMOVE SNAP
RING
REMOVE SNAP RING
POSITION OIL SEAL
USE THE PROPER
THEN USE SEAL
SIZE SEAL
DRIVER TO SEAT
PROTECTOR
SEAL SQUARELY TO
THE PROPER DEPTH
TO REMOVE BEARING
TO ALLOW SHAFT AND
BEARING TO DROP OUT
OF HOUSING
REMOVE GEAR, AND
PRESS BEARING
INNER RACE
7
. If necessary, remove the snap ring to separate the
gear and bearing from the shaft. Hold the gear and
bearing in one hand and tap the end of the shaft
vigorously with a soft mallet.
1
2. Position the input bevel gear in mesh with the output
shaft bevel gear. Tap the input shaft into place with
a nonmetallic mallet. Use one hand to hold the
gear and shaft to dampen the blows from the mallet.
Be sure gear is on the marked side of the housing.
Cleaning, Inspection and Repair
1. Clean all parts of grease, rust, or foreign material.
2
. Dry all parts. Compressed air may be used on all
parts EXCEPT BEARINGS.
13. Align the shaft and insert a ball bearing on each
bearing surface by hand.
3. Check bearings for smooth rotation, then lubricate.
14. Install new seals in the retainer caps using a driver.
4. Remove all burrs and scratches from shafts with a
fine file or stone.
15. Using seal protector # 670293 over the shaft serrated
ends; install new gaskets and the bearing cap.
Tighten retaining cap screws to 8-11 ft. lbs. (27.3 -
5
6
7
8
. Check housing for cracks or pulled metal.
1
4.7 Nm).
. Replace all snap rings.
16. Lubrication: See the Lubrication Chart in
Chapter 1.
. Replace all oil seals.
. If separated, install the inside ball bearing and bevel
gear on the output shaft. Be careful of alignment.
The use of a press is preferable to installing bearings
and seals with a mallet.
1
7. Install the gasket and cover and secure with self
tapping screws. Torque to 20-24 in. lbs. (2.3 - 2.7
Nm).
1
8. Align scribe marks and install “T” Drive on the
equipment.
1
08
CHAPTER 20. 1100 SERIES DRIVES
It is recommended that you take
special notice of all items
DISASSEMBLY
WARNING
discussed in this manual and wear the appropriate
safety equipment. Failure to do so may result in
death or serious injury.
SNAP RING BEARING ASSEMBLY
SEAL
"O" RING
GEAR
Use approved safety procedures
SHAFT
WARNING
with equipment for removal/
installation of axles, keyways and hardened shafts.
Remove all burrs and sharp edges with a honing
stone or crocus cloth before installation. Failure
to do so could result in equipment damage, death
or serious injury.
CAGE
GENERAL
SNAP RING
"O" RING
1. Scribe marks on the covers and shafts to aid in
reassembly.
I.D. TAG
2. Clean and check all shaft ends before removing
the cap and cage assembly.
MAIN HOUSING
CAP
OPTIONAL
VENT
RING
O" RING
"
O" RING
RING
CAGE
"
CAGE
3
. Remove the four input cage bolts and remove the
input cage; the assembly will follow.
The 1100 series angle drive is a heavy duty gear box
used with larger equipment with horse power ratings
up to 20 H.P. This unit is of cast iron construction for
strength featuring tapered roller bearings for longer
life. It can be configured wither as a right angle drive
with right or left handed rotation, or a “T” drive.
Reassembly is the reverse of the disassembly
procedure.
4
. To disassemble the input cage assembly, first remove
the nut and washer that holds the large keyed
gear onto the shaft. With an outside puller, if
necessary, remove the gear. The roller bearings
will be attached.
109
1
0. Remove the snap ring.
5
. Remove bearing from gear by using a bearing splitter
and puller.*
11. On the other end, use the same puller and remove
both the keyed gear and bearing at the same time.
6
. Remove the shaft out of the cage. Remove roller
bearing with outside puller toward threaded side. *
Then remove the snap ring.
12. Remove the snap ring.
*
When roller bearings and races are removed with a
SOFT PLUG
bearing puller, discard and do not reuse.
SNAP RINGS
7
. To remove the races, simply tap out with a punch
and hammer. The large snap ring will be left in the
cage when all parts are removed.
13. To remove the 1-3/4'’ (44.5 mm) soft plug, simply
tap it out of the case. Discard the old plug.
1
4. To remove races, simply tap the race out of the
cap and pry the crush ring out. The other race
can be tapped out with a punch and hammer. If
the unit is not equipped with a plug, very carefully
pry the race and crush ring out of cap and discard.
INSPECTION
Clean all parts in cleaning solvent. Examine for wear
or damage and replace as needed.
8. Remove the output cap and the assembly will follow.
9.
To disassemble the output shaft assembly, first
remove the bearing that is located under the cap
on the shaft, by using an outside puller.*
NOTE
Do not hook a puller on the snap ring.
1
10
REASSEMBLY
CRUSH RING
It’s very important when assembling this unit that you
use all new seals and “O” rings.
WOODRUFF KEY
SNAP RINGS
CAP
5.
Before installing the cover, first install a new crush
ring into the cover. Press a new race up to the
crush ring. To properly set up the output shaft
preload, place the shaft into the case, and place
the cover over the shaft without the case/cover
shim and “O” ring. Tighten the four bolts to a torque
of 200 in. lbs. (22.6 Nm) at 50 inch pound (5.65
Nm) increments.
1.
Following the scribe marks, press the keyed gear
on if necessary, and replace the snap rings on
the output shaft.
6.
Now remove the cover and place a new case/cover
shim with a new “O” ring and torque to 200 in lbs.
(22.6 Nm) at 50 inch pound (5.65 Nm) increments.
SOFT PLUG
2.
Make sure the inner bearing race is used when
pressing roller bearings into place.
NOTE
Service bearings for this unit may have a shim in the
box along with a new outer race. When pressing the
bearing next to the gear, place the shim for that bearing
and race (if present) next to the gear first, then press
in the race and bearing.
7. To install a 1-3/4'’ (44.5 mm) soft plug, tap in
carefully with the lip up until 1/16'’ (.34 mm) below
flush is achieved.
BEARING RACE
"O" RING
"O" RING
SNAP RING
CAGE
BEARING RACE
8
.
.
To assemble the cage assembly, place the large
snap ring in its mounting area in the cage. Press
the small race to the snap ring from the outside.
3
.
.
Install the other bearing that fits into the cap without
the shim.
4
The race that is used with a roller bearing on the
gear side mounts into the case. Press the race in
carefully until seated.
9
Press the large race into the cap.
NOTE
Make sure that all races and roller bearings are kept
together as provided.
111
WOODRUFF KEY
SNAP RING
ROTATE CAGE WHILE
TIGHTENING NUT
10. Place a small snap ring on the shaft.
1
1. Press a roller bearing on the shaft to the back
side of the snap ring and do not use a shim. Install
the woodruff key.
1
4. To achieve a proper pre-load on the bearings, place
the outboard side of shaft in a protected jawed
vice. Begin to tighten the nut on the gear side,
while turning the cage until a very slight drag is
achieved. Tighten so the bearing in the cage housing
does not have end play and the parts should spin
freely.
GEAR
SHIM
IF REQUIRED
BEARING
1
5. After loading to the bearing is done, place a new
“
O” ring around the outer diameter of the cage
and position it in the case. Reinstall bolts and
tighten to a torque of 200 in. lbs. (22.6 Nm).
1
2. Press a large shim and a new large roller bearing
onto the gear pressing on the inside bearing race.
1
6. To install seals, use a 1'’ seal protector. Position
seals so that they are installed .100" (2.5 mm)
below flush.
"O" RING
LUBRICATION
After assembly, fill with 1 pt. (473 ml) E.P. 90 gear oil.
"O" RING
1
3. Place the shaft into the proper position in the cage,
and place the gear with the bearing onto the shaft.
1
12
1100 SERIES DRIVE
LUBRICATION
Oil Bath
1
6 oz. (473 ml) S.A.E. E.P. 90 Oil
Part No. 730229B
The above illustration is supplied as a general assembly guide, your model may be different based on
manufacturers requirements.
113
CHAPTER 21. SHIFTING ASSEMBLY
It is recommended that you take special notice of all items discussed in this manual
and wear the appropriate safety equipment. Failure to do so may result in death or
WARNING
serious injury.
Use approved safety procedures with equipment for removal/installation of axles, keyways
and hardened shafts. Remove all burrs and sharp edges with a honing stone or crocus
cloth before installation. Failure to do so could result in equipment damage, death or serious injury.
WARNING
KEY SPRING HEIGHT
To check shifting keys for loss of spring height, place the short flat portion of a key on a flat surface as shown,
measure the distance from the surface to the key tip. The measurement should be from .400" to .460" (10.2-
11.7 mm); if the measurement is below .400" (10.2 mm) the key should be replaced.
VERTICAL INPUT
.
.
400 (10.2 mm)
460 (11.7 mm)
H-SHIFT PATTERNS
IN-LINE SHIFT PATTERN
HORIZONTAL INPUT H-SHIFT PATTERNS
7
8
9
9
00 SERIES
00, 820 SERIES
00, 910, 915, 920,
30 SERIES
MST SERIES
6
00 SERIES
(
2
AVAILABLE IN
to 8 SPEEDS)
FIGURE SHOWS
5
SPEED UNIT
LEFT HAND INPUT
SHIFT LEVER ASSEMBLY
RIGHT HAND INPUT
1
1
2
200 SERIES
700 SERIES
000 SERIES
1
2
700 SERIES
000 SERIES
NO LEFT
HAND INPUT
200 SERIES
1
2
300 SERIES
2300 SERIES
1
14
GENERAL
REASSEMBLY
1
. Prior to removing a shift lever assembly from a
transaxle, make note of the position of the shift
lever so that it may be assembled correctly to the
shift lever housing.
1. DOWEL PIN TYPE. Secure with a new dowel pin.
A second dowel pin is used in some assemblies
for alignment. This dowel pin is located on the gasket
surface of the shift lever housing and fits into a
mating hole in the transaxle.
2
Move the shift lever to Neutral, if possible, before
removing it from the transaxle. Clean around the
lever housing to prevent dirt from falling into the
transaxle. Cover this opening by inserting a clean
rag with a screwdriver.
QUAD RING SEAL
ROLL PIN
HANDLE END
SHIFT LEVER
DISASSEMBLY
RETAINER
1
. Place the shift lever in a vise so the shift lever
housing is at least one inch from the top of the
vise jaws.
SNAP RING
SHIFT LEVER
HOUSING
QUAD RING SEAL
SHIFT LEVER
SHIFT LEVER
2
. SNAP RING TYPE. Secure parts with the snap
ring. Before installing the shift lever and housing
into the transaxle housing, ensure the shifting forks
are in the neutral position.
ROLL PIN
3. Always use new gaskets between the shift lever
housing and the transaxle.
SHIFT LEVER
RETAINER
DOWEL PIN
SHIFTING ASSEMBLY
GENERAL
1
. Differences in assemblies will be noted in the
following servicing procedure. Always use the parts
list for each model to obtain the correct parts.
2
. DOWEL PIN STYLE. Locate the dowel pin holding
the retainer in the housing from the outside. Place
a 1/4'’ (6.3 mm) flat face punch on the gasket
surface directly over the dowel pin. Strike the punch
firmly with a hammer to dislodge the retainer from
the shift lever housing. Always use a new dowel
pin for reassembly.
NEUTRAL GROOVE
SHIFTER FORK
DETENT BALL
AND SPRING
SHIFTER
STOP
SNAP RING
SHIFTER ROD "A"
SNAP RING
3
. SNAP RING STYLE. Use a snap ring pliers for
removing the snap ring; loosen the vise and
disassemble the pieces.
4
. Remove the shift lever from the shift lever housing.
Examine the roll pin in the ball of the shift lever. If
bent or worn, replace. When inserting a new roll
pin in the ball, position so equal lengths protrude
from both sides of the ball.
SHIFTER ROD "B"
SHIFTER FORK
DETENT BALL
AND SPRING
NEUTRAL GROOVE
5
. Oil leakage past the point where the shift lever
enters the shift lever housing will require
replacement of the quad ring seal in the shift lever
housing.
3
Stop, 3-Speed Transaxle Shifter Rod & Fork Assy.
Prior to reassembly, be sure the bends in the shift
lever correspond to the mounting on the vehicle.
115
NEUTRAL GROOVE
SHIFTER FORK
NEUTRAL GROOVE
SHIFTER STOP
INDEXING BALL
AND SPRING
SHIFTER
STOP
SHIFTER ROD "A"
SPRING
SNAP RING
SNAP RING
DETENT
BALL
SHIFTER ROD "B"
SHIFTER FORK
NEUTRAL GROOVE
INDEXING BALL
AND SPRING
4
Stop, 4-Speed Transaxle Shifter Rod & Fork Assy.
SHIFTER FORK
2
. Shifting assemblies are removed from and installed
into the transaxles by squeezing the top end of
the shifter rods. This causes a binding that retains
all parts during removal or installation.
3
. Slide the shifter fork into the shifter rod until it
lines up with the hole with the detent ball and spring.
With a flat blade screw driver, press the detent
ball into the hole and move the shifting fork
completely onto the shifter rod.
INSPECTION
1
. Replace the shifter stop if worn or damaged.
4
. Move the shifting fork to the neutral position. The
neutral groove is the center groove. If the shifter
rod has four grooves, the neutral groove is the
second groove from the shortest end. This neutral
groove can be seen through the hole in the shifter
fork.
2
. Examine the teeth and the internal splines of the
two shifter gears. Replace damaged gears. The
gears must slide freely on the shifter shaft.
Excessive wear of the internal spline of the gears
will create cocking and difficult shifting. Replace
the gear if this condition is present.
3
. Replace the shifter shaft needle bearings if wear
is evident. See Chapter 22 on bearings for removal.
Replace if the bearing surface of this shaft should
be scuffed, pitted or worn to a diameter less than
SNAP RING
SHIFTER RODS
ANNULAR
GROOVE
.
750'’ (19.1 mm).
4. Replace other parts showing wear, looseness,
cracks, etc...
DISASSEMBLY
NEUTRAL POSITION
To disassemble the shifter and fork assembly, use
the assembly procedure in reverse.
SHIFTER FORKS
ASSEMBLY
1
. Reassemble the shifting assembly by following
the illustrations. Lay the parts on the bench on a
clean paper or shop cloth. Pay particular attention
to the annular grooves in the shifter rods and snap
rings.
ANNULAR GROOVE
SHIFTER
STOP
SNAP RING
5
. When the shifter forks are properly assembled to
the shifter rods and positioned in neutral, the ends
of the notches in the shifter forks are in alignment.
NEUTRAL GROOVE
SHIFTER FORK
DETENT BALL
AND SPRING
SHIFTER ROD "A"
SNAP RING
SHIFTER
STOP
SNAP RING
SHIFTER ROD "B"
SHIFTER FORK
NEUTRAL GROOVE
DETENT BALL
AND SPRING
2
. Assemble the shifter forks onto the shifter rods.
The shifter forks are interchangeable.
1
16
Tecumseh Transmissions
Shift Key Quick Reference Guide
Service No.
Length
Where Used
Shape and Size
shown actual size)
(
7
92071
2.950"
500s
7
.493 cm
7
92089A
2.625"
.668 cm
700/800/801/910
6
7
92094
2.812"
.142 cm
728/A/729/A/757/A/759/780/792
7
7
7
92018
3.165"
.039 cm
900s
8
92123A
3.980"
0.109 cm
820/920/930
1
7
7
92136A
92131
3.980"
0.109 cm
820/930/MST
820-014/A
1
4.040"
0.262 cm
1
117
CHAPTER 22. BEARING AND BUSHING SERVICE
GENERAL BEARING AND BUSHING CARE
NEEDLE BEARING SERVICE
It is advisable to use an arbor press to remove and
install needle bearings.
1
. Bearings, bushings and bearing surfaces should
be thoroughly cleaned prior to examination. Examine
closely for scuffing, wear, pitting, and abnormal
conditions. Replace if any of these conditions appear.
2
. Use clean, filtered solvent to clean bearings. Then
use a clean, lint free cloth to dry the bearings.
Immediately coat the cleaned bearings with lubricant
to prevent oxidation and corrosion. If the bearing
is to be stored, wrap in oil proof paper until needed.
3
. Take care of bearings in the case and cover. Cover
them to keep out any foreign material. Place the
gasket surface down on clean paper and cover with
a clean cloth. Never clean the lubricant from new
bearings. This lubricant prevents damage before
the transaxle lubricant enters the bearing.
BALL BEARING SERVICE
1
. Use a bearing tool to press out the bearing. Insert
the proper tool in the bearing, and with an arbor
press, press out the bearing from the inside.
The ball bearings used in the outer ends of the axle
supports are sealed. Without removing the bearings,
but with the axle removed, rotate the inner race with
your fingers. If any roughness is noted, replace the
ball bearing assembly. These ball bearings are factory
lubricated and additional lubrication cannot be added.
When driving in these ball bearings, use the proper
tool that drives on the outer race as shown on the
next page.
2. When installing open end needle bearings, always
apply pressure to the stamped side.
3
. Use only recommended tools to insert bearings.
The opposite end of the same tool used for removal
is used for replacement.
1
. Install the needle and ball bearing combination for
the input shaft into the cover prior to the installation
of the input shaft.
4
. The inside face of the bearing housing should be
below the thrust face on the case or cover. This
distance is controlled by the design of the inserting
tool. By using the proper tool, the bearing will be
protected upon installation. Bearings should be
pressed into the cover .015'’ to .020'’ (.381-.508
mm) below the thrust surface. The open end bearing
in the low speed shaft of four speed transaxles is
to be .010'’ (.254 mm) below the thrust surface.
The open end bearing in the shifter shaft should
be .010'’ (.254 mm) below the end as well.
2
. Using a socket or bearing installer, install the input
shaft ball bearing into the case by driving on the
outer race. After the input shaft bearings are
installed, assemble the input shaft. Press the input
shaft into the bearing combination while supporting
the inner race of the ball bearing on a hollow tube.
1
18
9
. Insert a 7/16'’ (.438 mm) metal rod into this bearing.
With a mallet strike the rod sharply to compress
the wet paper. Continue to add more wet paper,
this will hydraulically lift the bearing out of the
shaft.
1
0.Use the authorized tool listed below to install the
new bearing. Needle bearings in shifter shafts should
be installed .010'’ (.254 mm) below flush.
5
. To remove the needle bearing in the splined shifter
shaft, proceed as follows:
NOTE
Blind bearing pullers are available to remove this
bearing. There is a space between the bottom of the
drilled hole and the inside end of the bearing to
accommodate the ridges of the bearing puller.
6
. With the needle bearing up, clamp the splined
shifter shaft vertically in a soft jaw vise so the
lower end of the shaft rests on a block of wood.
7. Prepare some pieces of paper toweling, newspaper,
etc. by soaking in water.
8
. Tear paper into pieces, approximately one to two
inches square. Stuff these wet pieces of paper
into the needle bearings until full.
BUSHING SERVICE
When removing bushings, use the combined bushing
remover and installation tool. Position the piece to be
serviced on the table of an arbor press with an opening
to allow the bushing to pass through.
1. Use the proper tool as illustrated.
2
. The bushings in the three gear cluster, four speed
transaxle are both removed at the same time. The
bushing from one end will contact the bushing in
the opposite end and both may be pushed out.
3
. Use an arbor press and push the steel ball through
the new bushing to expand it to the required size.
6
70234
670207A
670213
6
70203
6
70210
6
70209
670211
6
70263
6
70206
6
70251
6
70204
670252
6
70205
PEERLESS TOOL KIT 670254A
Tool No.
Description
Oil Seal Installer
Bushing Driver and Installer
Bushing Driver and Installer
Oil Seal Protector
Bearing Driver and Installer
Oil Seal Installer
Bearing Driver and Installer
Oil Seal Installer
Bearing Driver and Installer
Bearing Driver and Installer
Bearing Installer
Bearing Driver
Oil Seal Protector
Oil Seal Protector
Use with:
6
6
6
6
6
6
6
6
6
6
6
6
6
6
70203
70204
70205
70206
70207A
70209
70210
70211
70213
70234
70251
70252
70262A
70263
Seal with 13/16" (20.64 mm) I.D.
Bushing with 3/4" (19.05 mm) I.D.
Busing with 1-1/2" (38.1 mm) I.D.
Seal with 1/2" (12.7 mm) I.D.
Bearing with 5/8" (15.87 mm) I.D.
Seal with 21/32" (16.7 mm) I.D.
Bearing with 1/2" (12.7mm) I.D.
Seal with 1/2" (12.7 mm) I.D.
Bearing with 9/16" (14.29 mm) I.D.
Bearing with 5/8" (15.87 mm) I.D.
Input Bearing on 800 Series
Bearing with 11/16" (17.46 mm) I.D. - 800 Series
All 3/4" (1.8 mm) Axle Shaft Seals
Seal with 5/8" (15.87 mm) I.D.
119
CHAPTER 23. VST TROUBLESHOOTING
The information on the following pages has been provided to help understand the internal operation of the VST.
Do not use this information to attempt any internal repairs. Tecumseh's current policy on hydrostatic transaxles
that have internal failures is to replace the complete unit. This has not changed. However, we would like to
provide a failure checklist to assist in making an accurate evaluation of the complete tractor to eliminate any
unnecessary replacements. Here is a list of items to check and corrective actions to take.
To properly test the unit for power loss.
1.
2.
3.
4.
Allow the unit to cool before trying the following steps.
Put the shift lever in a position that is 1/2 (12.7 mm) of the travel distance from neutral to forward.
Place the tractor on a 17 degree grade.
Drive the tractor up the grade (without the mower deck engaged). The loss of power experienced should
be approximately 20%. This is considered normal. If the loss of power is approximately 50%, this would
be considered excessive.
5.
Bring the unit to neutral, shift into forward and note the response. Care should be taken to move the
lever slowly to avoid an abrupt wheel lift.
To determine if the problem is with the hydro unit, all external problem possibilities must be eliminated. Here
are some potential problem areas.
1.
Overheating: Heat can cause a breakdown in the viscosity of the oil which reduces the pressure used
to move the motor. Remove any grass, debris, or dirt buildup on the transaxle cover and/or between the
cooling fins and fan. Buildup of material will reduce the cooling efficiency.
2.
Belt slippage: A belt that is worn, stretched, or the wrong belt (too large or wide) can cause belt
slippage. This condition may show the same loss of power symptom as overheating. Typically, the unit
which has a slipping belt will exhibit a pulsating type motion of the mower. This can be verified visually
by watching the belt and pulley relationship. If the belt is slipping, the belt will chatter or jump on the
pulley. If the belt is good, a smooth rotation will be seen. Replace the belt and inspect the pulley for
damage.
3.
Leakage: The VST and 1800 Series have two oil reservoirs which can be checked for diagnostic
purposes. The first is the pump and motor expansion bellows, With a small diameter blunt or round
nose probe, check the bellows depth through the center vent hole. Proper depth from the edge of that
hole is 3-1/4 - 3-1/2 inches (8.25 - 8.9 cm).
The second chamber is for the output gears including the differential. FIRST make sure the tractor is
level, then remove the drain/fill plug. NOTE: Some units that do not have differential disconnect will have
two plugs. We recommend using only the primary plug. Insert a small pocket rule until you touch the
bottom of the case. Remove it and check for 1/4 - 3/8 inches (6.5 - 9.5 mm) contact; this is full at its 8
oz. (236 ml) capacity.
1
20
4.
Low ground speed: If the linkage is not synchronized to absolute neutral, or the shift lever is not
properly fastened to the tapered control shaft, full forward travel may not be achieved. This may cause
a false reading and be misdiagnosed as a low power condition. This also could be caused by the brake
not releasing.
To determine absolute neutral, the hole in the tapered control shaft must face straight up and down. At
this point make sure the OEM linkage is in neutral. To properly fasten the control lever to the shaft,
torque the nut to 25-35 ft. lbs. (34 - 48.3 Nm) with the shaft and the lever in neutral.
When attaching the shifter arm to the shaft you must prevent any rotation during torquing. This can be
done by placing a long 5/16" (7.94 mm) bolt in the hole as shown in illustration. Hold the bolt until the
tapers are locked and the nut torque is correct.
To make sure that the brake is not binding, drive the unit up a slight grade. Position the speed control
lever into neutral. The unit should coast backwards. If the unit does not coast back slowly, the brake is
not released from the brake disk. Adjust the brake linkage to release the brake completely when the
foot pedal is released.
5.
Hard to shift: Typically, hard to shift symptoms are not caused by the hydrostatic unit. The shift arm
should move with relative ease. Check the ease of movement of the shift arm with a torque wrench. For
the following spec numbers, the reading should be 40-65 inch lbs (4.5-7.34 mm). measured at the end
of the shaft (205-006, 016, 021, 022, 030, 033, 036, 040, 046). If the model has a neutral spring, the
torque reading should be 70-150 inch lbs. (7.9-16.9 mm). All other models (without neutral return
spring) should read 150 - 120 inch lbs. (13.5-16.9 mm) measured at the end of the shaft. Binding may
occur in the linkage connections due to rust or moisture. Lubricating these connections and checking
for bent or damaged parts should resolve hard shifting.
PRODUCT CONTAINS PATENTED FEATURES
o
0 from case/cover
parting line is
9
o
neutral
0
9
Parting
Line
DIRECTION CONTROL SHAFT
DIRECTION CONTROL LEVER
POCKET RULE
FOR OIL CHECK
PUSH NUT
SQUARE CUT "O" RING
3
1
/8" (9.53 mm)
/4" (6.35 mm)
DIFFERENTIAL
DISCONNECT HOOKUP
3
¼" (82.5 mm)
3
½" (88.9 mm)
EXPANSION BELLOW'S
CHECK COLD FOR CORRECT DEPTH
NOTE: The above illustration is of a foot control unit with differential disconnect. Consult your parts list by model
and specification number to get correct parts for your unit. ALL PARTS SHOWN MAY NOT BE ON YOUR UNIT.
121
