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TECUMSEH & PEERLESS - Small Engine Suppliers

1. BUSHING 9 To assemble the output shaft assembly place a washer and then the bronze bushing with the collar 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 10 After both shafts are completed place the flanged bushings on each end Notice that one is larger than the other NOTE 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 BEARING BLOCK x Dy Jj A 12 Before installing the differential into the case apply Bentonite grease to the axle bearing areas SHIFT FORK FAN ASSY 13 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 11 3 Nm 14 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 t
2. This manual covers all Tecumseh Peerless gear products as follows 915 940 Series Transaxles T E H N 6 S H A N D B O K 100 Series Differentials MST200 Series Transaxles 920 Series Transaxles 300 Series Transaxles 930 Series Transaxles 600 Series Transaxles 1000 1100 Series Right Angle T Drives 601 Slow Speed Transaxle 1200 Series Transaxles 700 Series Transmissions 1300 Series Transaxles 700H Series Transmissions 2300 Series Transaxles 800 801 Series Transaxles 2400 Series Transaxles 820 Series Transmissions 2500 Series Transaxles 900 Series Transaxles 2600 Series Transaxles 910 Series Transaxles VST Transaxles Other illustrated Tecumseh 2 Cycle Engine 4 Cycle Engine and lom Ed charts are available T U M S amp RL SS For complete listing write or cal TRANSMISSION and DRIVE PRODUCTS TECUMSEH gt m ENGINES amp TRANSMISSIONS TECUMSEH 740045 Tecumseh Products Company Tecumseh Europa S p A ae Engine amp Transmission Group Strada delle 99 900 North Street 10135 Torino Italy ENGINES amp TRANSMISSIONS Grafton WI 53024 Tel 011 39 11 391 8411 Phone 262 377 2700 Telefax 011 39 11 3910031 FAX 262 377 4485 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 A WARNING WARNING indicates a p
3. WARNING We caution you against the use 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 GENERAL The 910 series is available with 1 speed forward and 1 reverse INPUT SHAFT COVER CASE ROD HEX SCREWS IDENTIFICATION This unit contains an aluminum tag showing the model number DISASSEMBLY OF TRANSAXLE 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 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 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 4 Remove the two brake bracket screws and remove brake assembly 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 grea
4. WS Pp lt lt 5 SNSSSNNS sk NSLS 9 SSH ai CA NN ANA S BALL BEARINGS 2 O RING SEAL ROLLER BEARINGS 2 U NOTE NO BEARING AT THESE POINTS NEEDLE BEARINGS 2 91 2500 SERIES TRANSAXLES ee SEAL MODEL and SERIAL NUMBERS HERE a Wi GEAR P e INPUT SHAFT Tuus e GEAR sh BZW RETI amp ans 169 or 9 Zon 9 46 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 772777777 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 va 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 GENERAL The 2600 series transaxle has infinite forward and reverse
5. 792131 4 040 820 014 10 262 117 CHAPTER 22 BEARING AND BUSHING SERVICE NEEDLE BEARING SERVICE It is advisable to use an arbor press to remove and install needle bearings GENERAL BEARING AND BUSHING CARE 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 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
6. ALLEN HEAD SET SCREW SPRING SENI BALL 6 Remove the set screw spring and detent ball DISASSEMBLY 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 2 When prying the crankcase from the crankcase cover use specified mount points Failure to do so may result in equipment damage 2 With a rubber or leather mallet tap down on the shift lever rod while removing the cover from the case 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 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 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 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
7. 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 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 TERMS USED AXLE The shaft which connects the wheel or hub to the differential unit and transmits force back to the wheels 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 BEARING BLOCK Strip Used to support the ring gear of the differential 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 BEVEL GEAR A gear with teeth ground on a diagonal so that when it meshes with a second bevel gear power 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
8. 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 670204 9 Insert 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 10 Use the authorized tool listed below to install the new bearing Needle bearings in shifter shafts should be installed 010 254 mm below flush 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 Usethe 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
9. 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 J 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 7 When shifting gears verify the EG clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury IG 3 DO NOT shift on a hill or when 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 2 5 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 INPUT SHAFT INDEX BALL SPRING AND 4 Cd SCREW IDENTIFICATION TAG COVER CASE HEX SCREWS NEUTRAL START SWITCH LOCATION OPTIONAL BRAKE BRACKET SCREWS BRAKE CAN BE ON RIGHT OR ON LEFT SIDE GENERAL The 930 series transaxle is very similar to the 920 series The 930 series is availab
10. arbor press and push the steel ball through the new bushing to expand it to the required size E 670207A 670213 670234 670210 nn 670206 670263 670205 PEERLESS TOOL KIT 670254A Tool No Description 670203 Oil Seal Installer 670204 Bushing Driver and Installer 670205 Bushing Driver and Installer 670206 Oil Seal Protector 670207A Bearing Driver and Installer 670209 Oil Seal Installer 670210 Bearing Driver and Installer 670211 Oil Seal Installer 670213 Bearing Driver and Installer 670234 Bearing Driver and Installer 670251 Bearing Installer 670252 Bearing Driver 670262A Oil Seal Protector 670263 Oil Seal Protector Use with 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 1 0 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 comple
11. damaged shift keys gears or shifter brake shaft missing or misadjusted belt guides see the OEM s specs o200 9 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 Seal retainers are not properly sealed Tighten axle housing tightened correctly Axles cannot be turned 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 Replace keys and check unit for additional damage Shifting washers in backwards Chamfered side on the inside diameter of the washer must face the tips of the keys Shifter Brake shaft keyways damaged Remove nicks and burrs from keyway Shift lever housing misaligned to case Check if alignment marks on unit are correctly positioned Also determine if bend on shaft is in correct position Equipment clutch not engaging Adjust clutch according to the operator manual of the equipment
12. 1 Install the needle and ball bearing combination for the input shaft into the cover prior to the installation of the input shaft 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 118 1 Usea 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 2 Wheninstalling 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 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 5 Toremove the needle bearing in the splined shifter shaft proceed as follows
13. 46 CHAPTER 7 910 Series Transaxles aede to em ic etl E bt tet ot dg 47 50 CHAPTER 8 915 Series 940 Series Transaxles 51 55 CHAPTER 9 920 Series Transaxles nt 56 60 CHAPTER 10 930 Series l rarsaxles eoe tee eos e io ops ed tete eese 61 65 CHAPTER 11 MST200 Series Transaxlaes s e 66 70 Checking Oil Level 71 CHAPTER 12 1200 Series Three Speed Transaxle 72 74 CHAPTER 13 1300 Series Hydrostatic Gear Reduction Differentials 75 77 CHAPTER 14 2300 Series Four Speed 78 84 CHAPTER 15 2400 Series Hydro Powered Transaxles 2 2 1 0 1 1 85 87 CHAPTER 16 2500 Series Hydro Powered Transaxles 22 2 1 1 1 1 0 88 92 CHAPTER 17 2600 Series Hydro Powered Transaxles 21 21 enne 93 97 CHAPTER 18 deese e 98 103 19 BEA E e de Le 104 108 CHAPTER 20 1100 Series DrIVess eo e e ee eal tee ete c
14. 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 COUNTERSHAFT ASSEMBLY OUTPUT SHAFT SHIFTER BRAKE SHAFT ASSEMBLY 8 There 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 SNAP RING GROOVE SNAP RING 9 Asthese 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 itis not necessary to remove the snap ring from the shaft 62 NEEDLE BEARING FLUSH WITH SQUARE CUT 7 135 3 43 mm 71150 3 81 mm THRUST WASHER BEVEL GEAR RETAINING RING 10 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
15. Reassemble the shifting assembly by following 2 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 E DETENT BALL SHIFTER ROD B DETENT BALL SHIFTER FORK AND SPRING Assemble the shifter forks onto the shifter rods The shifter forks are interchangeable 116 NEUTRAL GROOVE SHIFTER FORK 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 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 SNAP RING ANNULAR 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 Tecumseh Transmissions Shift Key Quick Reference Guide Service No Length Where Used Shape and Size shown actual size 792071 2 950 500s 7 493 cm a E 792089 2 625 700 800 801 910 6 668 cm 792094 2 812 728 A 729 A 757 A 759 780 792 7 142 cm 792018 792123A 820 920 930 792136A 980 820 930 MST 0 109 cm C
16. Shifter stop assembled backwards Determine that the notch in the shifter STOP aligns with shifter forks in the NEUTRAL position Shift gear chamfer is positioned on the Check that bevels on shifter gears are correct fork flanges wrong side 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 Gears improperly installed Check the exploded view for a correct assembly of parts 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 TROUBLESHOOTING TABLE Continued UNIT JUMPS OUT OF GEAR Gear teeth are worn beyond tolerances Replace worn gears Spring in shifter fork weak o
17. 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 is 400 10 2 mm 460 11 7 mm H SHIFT PATTERNS IN LINE SHIFT PATTERN HORIZONTAL INPUT H SHIFT PATTERNS 700 SERIES 800 820 SERIES 900 910 915 920 930 SERIES 600 SERIES MST SERIES AVAILABLE IN 2 to 8 SPEEDS FIGURE SHOWS 5 SPEED UNIT LEFT HAND INPUT RIGHT HAND INPUT SHIFT LEVER ASSEMBLY 1700 SERIES 1200 SERIES 3 1700 SERIES 2000 SERIES 2000 SERIES NO LEFT HAND INPUT 1200 SERIES 2300 SERIES 2300 SERIES 114 GENERAL 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 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 DISASSEMBLY 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 QUAD RING SEAL SHIFT LEVER SHIFT LEVER SHIFT LEVER RETAINER DOWEL PIN DOWEL PIN STYLE Locate the dowel pin holdin
18. arrangement 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 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 HYDROSTATIC UNIT MOUNTING HOLES VEHICLE MOUNTING HOLES COVER BRAKE SHAFT RIGHT SIDE HERE 4 INPUT SHAFT LEFT SIDE HERE AXLE SUPPORT RETAINING BOLTS SHORT AXLE HYDROSTATIC UNIT SUPPORT MOUNTING HOLE 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 Drainthe 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 DIFFERENTIAL UNIT NOTE POSITION OF CAP SCREW HEAD REASSEMBLE IN COVER SAME WAY DIFFERENTIAL DRIVE 47 PINION AND GEAR OUTPUT DRAIN PLU 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 sup
19. bearing race BLIND BEARING SNAP RING DRIVEN BEVEL GEAR ON OUTPUT 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 INSPECTION 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 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 LUBRICATION See the Lubrication Chart in Chapter 1 T DRIVE SERVICE 1 Before removing a T Drive from equipment be sure to scribe marks at one mounting hole to ensure correct reassembly T DRIVE WITH DIFFERENT INPUT AND OUTPUT ENDS OF INPUT SHAFT DRIVE MODEL NUMBER T DRIVE WITH IDENTICAL INPUT AND OUTPUT ENDS OFINPUT SHAFT 2 Todisassemble 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 Switching the 180 will result in
20. 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 OUTPUTGEAR BUSHING BUSHING 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 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 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 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 12 Guide the co
21. handling ball bearings See Chapter 22 Bearing and Bushing Service 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 LUBRICATION See Lubrication Chart in Chapter 1 LEFT HAND SZ SF Clockwise LEFT HAND RIGHT HAND Clockwise RIGHT ANGLE DRIVE ROTATION 105 SMOOTH COVER RIGHT ANGLE DRIVE 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 SHEET METAL OUTPUT SHAFT HOLE IN SEAL 2 Output shaft seal replacement Remove the seal by punching two small holes in the seal
22. the gasket DIFFERENTIAL gt INPUT SHAFT SHIFTER SHAFT SHIFTER GEAR CLUSTER Single Range without Lock Differential There are two different 2600 models as shown above SPACER THRUST BEARING ALI THRUST WASHERS REITING COUNTER SHAFT 7 Toremove components from the single speed version first remove the differential thrust washers drive gear input shaft countershaft output gear and shaft 93 8 Toremove components from the 2 speed with locking 4 Splines should allow a smooth fit Rotate meshing differential version remove the shifter rod and fork parts for a better fit if binding seems excessive the outside bolt spring and detent ball Next remove the high range gear then the shifter gear cluster Shifter Mechanism Dual Range and fork assembly together DIFFERENTIAL LOCK FORK ASSEMBLY HI LOW SHIFT 1 FORK AND ROD n ELIT TERRE ETE I 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 3 Inspect shifter fork for straightness and wear Differential 1 Make sure you have all parts 2 Check thrust washers for wear THRUST BEARING LOW RANGE INPUT SHAFT GEAR SPACER LOCK COLLAR AND PIN ASSY BALL BEARING 10 Remove shifter shaft output shaft and the output gear in this order 11 Remove differential and lo
23. 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 SHIFT COLLAR SHIFTER BRAKE SHAFT Vr 7 IB ESI ES ESI 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 LARGE INNER DIAMETERS FACE EACH OTHER LARGER RADIUS SPACER TOWARD SHIFT KEYS 19 REVERSE CHAIN AND SPROCKETS 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 NOTE There have been a few 900 models built with ide
24. 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 When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury A VARNIN J DO NOT shift on a hill or when 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 M 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 g We caution you against the use of aftermarket variations of braking sdhictm nts 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 CUSTOMER MOUNT POINTS PRY POINT GENERAL The MST Manual Shift Transaxle 200 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 It has a contoured case an
25. SZN KA KEN E7 Ni 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 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 2 If the unit will not turn freely note where the unit binds Check and replace those parts FOUR HEX HEAD RING GEAR BEARING RACE DIFFERENTIAL CARRIER 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 THRU BOLT HOLES RING GEAR DRIVE PIN DRIVE BLOCKS 5 Ifa snap ring is used the axle assembly may be disassembled If the axle end has been rolled do not attempt to break the rolled ret
26. The brake pads and brake disc must be free of grease and oil The brake and linkages may vary Follow recommended guidelines 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 700H SERIES TRANSMISSION OUTPUT SFRIDCKET y BUSHING 70 THBUST WASHER 7 ath SHIFT SPUR GEAR S ae 26 3rd SHIFT v OG SPUR BEAR nd SHIFT WASHERS 050 ds hamer on im me a dewneler of wealers 7 THIN SHIFT COLLAR must fare kaye i12 i DI E Tat SHIFT SPUR GEAN Bj Tp BUSHING Q e THRUST WASHER S wh 2 SHIFTER EO mem amp d BRAKE SHAFT 1 SHIFTER 1 1 SES fa d Z THO SHF CINLAR REVERSE GEAR GEAR Thick coker owani eval DE Thick toler toward hey THRUST defen WLC _ THRUST WASHER 2 e z ant _ BUSHING 9 SPACERS USED IN SOME MODELS LUBRICATION Permanent Lubrication 12 oz 355 ml Bentonite grease Part No 788067C ANPUT SHAFT 60 0QCPCD 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 A WARNING It is recommended that you take spec
27. 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 REASSEMBLY It s very important when assembling this unit that you use all new seals and O rings SNAP RINGS WOODRUFF KEY 1 Following the scribe marks press the keyed gear on if necessary and replace the snap rings on the output shaft 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 3 Install the other bearing that fits into the cap without the shim 4 Therace that is used with a roller bearing on the gear side mounts into the case Press the race in carefully until seated NOTE Make sure that all races and roller bearings are kept together as provided CRUSH RING 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 wi
28. a gear train BRAKESHAFT SHIFTER BRAKESHAFT The shaft ona 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 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 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 aramp for shifter key compression through the shift washer prior to gear engagement The chamfer in the washer is either stamped or machined in COUNTERSHAFT A splined shaft which hold spur gears that are in constant mesh with shift gears and transfer input power to the shift gears 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 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 DIFFERENTIAL GEA
29. 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 Ibs 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 Ibs 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 Ibs 7 9 16 9 mm All other models without neutral return spring should read 150 120 inch Ibs 13 5 16 9 mm
30. 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 Center one 1 32 794 mm thick by 7 8 19 mm 1 0 thrust washer on cover shifter shaft bearing Install the shifter assembly as a unit into the cover 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 1 32 794 mm THRUST WASHER 3 GEAR CLUSTER 10 With the small gear of the three gear cluster toward TURN CW 11 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 1 1 2 to 2 38 51 mm 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 ofthe case goes over the shaft rods in the opposite manner from which it was removed 12 Once in position if the case hangs up 1 2 to 1 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 SHIFTING _ MD FORKS IN NEUTRAL 13 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 14 Align the case and cover with the two dowel pins then install and tig
31. end SPUR GEARS SPLINE FOR CHAIN SPROCKET GEAR 1 B ii J ri 5 2 ALT FLANGED BUSHING NOTE 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 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 FLANGED SQUARE CUT O RING FLANGED SHIFTER BRAKE BUSHING SHAFT BUSHING N SN 9 49 SPUR GEAR S SPROCKET COLLAR 5 S xS M RS lt Q A SS SN SN at PAS ARN N 95 M XE WS Y N 55 NES Y 15 t N COUNTERSHAFT SPROCKET COLLAR SQUARE CUT O RING 6 With the ends of the countershaft and shifter brake shaft angled together install the countershaft sprocket and chain on the countershaft THICKER SQUARE FLAT COAT AREA WITH GREASE 7 Forcorrect positioning of the needle bearings use the removal installation tool Tecumseh part 670252 Fill the area between the needle bearings with axle grease before installing on the countershaf
32. input shaft The needle bearing on the inboard side is installed 135 150 3 43 3 81 mm below flush 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 SNAP RING KEYS 2 OR 4 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 REVERSE CHAIN AND SPROCKETS SPROCKET COLLARS fet SHIFT COLLAR NEUTRAL SPACER 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 th
33. 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 44 SHIFT WASHERS SS SHIFTING GEARS CUT OUT SIDE OF GEAR MUST FACE OUTBOARD END OF SHAFT 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 FLAT SIDE OF GEAR MUST FACE SHOULDER ONSHAFT NOTE As all the gears are placed back into the assembly each should be packed with bentonite grease BUSHING 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 Onthe shifter brake shaft place a large thrust washer next to the smallest shifting gear next the bronze bushing and then an 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 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 ring WASHER WASHER
34. 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 OPTIONAL INPUT LOCATION A INPUT uam pd SHAFT COVER CASE HEX B INPUT BRAKE BRACKET SCREWS SHIFT ROD NEUTRAL START SWITCH LOCATION OPTIONAL GENERAL 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 IDENTIFICATION TAG IDENTIFICATION This unit contains an aluminum tag showing the model number DISASSEMBLY OF TRANSAXLES 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 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 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 4 Remove the ring from the top of the shifter rod I
35. 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 69 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 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 Avoid blocking oil passages leading to axle shafts when 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 8 Tosealthe 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 seallbearing pocket area These new se
36. 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 2 Shafts and Axles a Check surfaces for rust pitting scratches or wear b Check keyways splines threads and grooves for wear Replace parts if worn or damaged beyond a refinished state 3 Case and Cover 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 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 Shifting Assembly Refer to Chapter 210n shifting assemblies 6 Gaskets Replace all gaskets 7 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 8 Bearings and Bushings Refer to Chapter 22 on bearings and bushings ASSEMBLY BRAKE SHAFT BEARING LOW GEAR SHAFT BEARING DIFFERENTIAL 1 32 794mm THICK 3 4 19mm 1 0 THRUST WASHER BETWEEN GEAR AND BEARING INPUT SHAFT AND GEAR FLAT SIDE OF GEAR UP 1 Instal
37. proper sabing turn screw two full M lures remeer from Hushi E BLISHINE FOL 2 THRUST WASHER BUSHING Ag A 2 a THRUST WASHER 5 5 bo ind ni SPUR BEAR fy WASHERS Se 4 ICharr om iusde EN lar SPUR GEAR tii washers 5 i e iameter n 4 SONO SHIFTING WASHERS AGUNDED SIDE TWARIS KEYS D must fate key E bd wa and BRAKE SHAFT a oP m hs Lat x SPUR m EV 7 SHIFTER KEYS 9 Aw y SHET COLLAR Thick part in mmwnarch bey REVERSE GEAR Vihirk collar tran ire OM THRUST WASHER BUSHING 7 OUTPUT 3 SPR CKET e BRACES USED IN SOME MODFLS NOTE These models can be built with brakes and sprockets either on right or left side ODay INPUT SHAFT mr LUBRICATION Permanent Lubrication 12 oz 355 ml Bentonite grease 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 JW 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 TWN When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury 719
38. retaining cap screws to 8 11 ft Ibs 27 3 14 7 Nm 16 Lubrication See the Lubrication Chart in Chapter 1 17 Install the gasket and cover and secure with self tapping screws Torque to 20 24 in Ibs 2 3 2 7 Nm 18 Align scribe marks and install T Drive on the equipment CHAPTER 20 1100 SERIES DRIVES J 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 7 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 GENERAL The 1100 series angle drive is a heavy duty gear box used with larger equipment with horse power ratings up to 20 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 DISASSEMBLY SNAP RING BEARING ASSEMBLY 1 Scribe marks on the covers and shafts to aid in reassembly 2 Clean and check all shaft ends before removing the cap and cage assembly 3 Remove the fou
39. 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 Before removing a unit Transmission product from any equipment look for and ask the customer about 1 Loose worn or glazed drive belts 2 Amisadjusted or badly worn clutch or belt tension Loose lost set screws and or sheared keys in drive driven pulleys or axle Oil saturated drive belts or clutches Bad operating habits such as clutch riding or not clutching when shifting Oil leaks If possible operate the equipment to help isolate the problem 8 Review Service Bulletin 304 ak NO 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 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 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 5 If the shifter lever will inter
40. seal may be cut AFTER ASSEMBLY 1 To install the brake shaft oil seal using a seal protector 2 To install the shifter rod oil seal use seal sleeve 670206 and driver 670211 3 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 the 2500 orient the unit to a 90 angle to the axles There should be no fluid leak 4 Install the drive assembly according to the manufacturer s instructions LOW RANGE TRANSMISSION DRIVE GEAR HYDROSTATIC DRIVE MOUNTING SURFACE 2 ET f DRIVEN f S INPUT GEAR lt gt ire 4 HIGH RANGE TRANSMISSION Aor LUZ 4555 DRIVE GEAR SPACER A 2 NN THRUST BEARING ies Ah A SPACER OR SHOULDER Dk aS EN eh INPUT SHAFT Y TABBED THRUST WASHER SHIFTER AND BRAKE SHAFT OIL SEAL BEVELED SIDES OF GEARS oo OUTPUT SHAFT TABBED THRUST TABBED THRUST WASHER WASHER THRUST WASHER THRUST SEAL WASHER 5 6
41. spur gears thrust washer and flanged bushing The spur gears are splined to the countershaft 31 FLANGED BUSHING SPROCKET SHIFTER BRAKE SPLINE FOR DISC BRAKE SQUARE CUT FLANGED BUSHING SQUAR CUT RING SHIFT COLLAR SHIFT WASHER THRUST WASHER SHIFTER GEARS 11 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 FLANGED BUSHING DIFFERENTIAL WASHER BUSHING 12 Remove the differential from the case Remove the 2 seals needle bearings or ball bearings 2 32 OLD STYLE NEW STYLE SEALED BALL BEARING SQUARE CUT O RING 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 are interchangeable All needle bearings must be repacked with grease Never use Bentonite grease in ball or needle bearings use wheel bearing grease NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT 2135 3 43 mm 2272221507 3 82 mm THRUST WASHER BEVEL GEAR RETAINING RING 13 To disassemble
42. 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 SHIFTER BRAKE SHAFT ASSEMBLY SLEEVED NEEDLE BEARINGS DIFFERENTIAL NEEDLE BEARING BEARING SLEEVE O RING OUTPUT GEAR O RING PU on THRUST BEARING WASHER SLEEVE NEEDLE BEARING WASHER 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 SHIFTER BRAKE SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY L 7 INPUT SHAFT 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 C SNAP RING om BALL BEARING INPUT SHAFT NEEDLE BEARING SEAL musr WASHER Large E 0 RING y musr WASHER Small THRUST BEARING WASHER THESE CUPPED THRUST AREAS WASHER GREASE INPUT PINION SNAP RING 8 DIFFERENTIAL Refer to Chapter 18 on differentials for service Should disassembly of the differential be necessary 2 oz 59 ml of bentonite grease should be placed around the gears on reassembly 38 REASSEMBLY NO
43. 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 COUNTERSHAFT BUSHING OUTPUT GEAR BUSHING PINION GEAR BUSHING WASHER WASHER 8 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 9 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 BUSHING MN 1 NEUTRAL SPACER SHIFTER GEAR SHIFTER COLLAR 10 DIFFERENTIAL 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 BEARING BLOCKS N BEVEL PINIONS RING GEAR WASHER 11 INPUT SHAFT 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 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT NEEDLE BEARINGS 135 3 43 mm 77777150 3 81 mm THRUST WASHER BEVEL GEAR RETAINING RING Tool par
44. 11 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 LOW GEAR SHAFT BEARING OUTPUT GEAR AND SHAFT DIFFERENTIAL ASSEMBLY BRAKE SHAFT 2 GEAR CLUSTER 12 Remove the two gear cluster and spacer from the brake shaft 13 Lift the differential unit out of the cover NOTE Service information appears in Chapter 18 on differentials 1 16 1 58 mm THICK 15 16 23 8 mm I D THRUST WASHER DIFFERENTIAL AND AXLE ASSEMBLY REMOVED OUTPUT GEAR AND SHAFT 14 Remove the output shaft and gear and thrust washer from each end of the shaft 80 1 32 794 mm THICK 1 19 mm 1 0 THRUST WASHER IDLER GEAR DLER GEAR CHAMFERED SIDE UP AWAY FROM BEARING 15 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 DIFFERENTIAL LOW GEAR SHAFT BRAKE SHAFT BEARING CARRIER BEARING 1 32 794 mm THICK 3 4 19 mm 1 0 THRUST WASHER INPUT SHAFT AND GEAR FLAT SIDE OF GEAR UP SHIFTER ROD SOCKETS MAGNETIC DRAIN PLUG BEARING TO BE 015 020 381 508 mm BELOW THRUST SURFACE 16 Remove the input shaft from the case by tapping with a non metallic hammer INSPECTION AND REPAIR 1 Gears a Check bevels for evidence of damage due to improper shifting NOTE Input
45. 13 6 Bolt 5 16 18 Axle Support Housing 2300 Series 180 216 20 4 24 5 Bolt 1 4 20 Differential 2300 Series 84 120 9 5 13 6 Bolt 3 8 16 Axle Support Housing 2300 Series 240 312 27 2 35 4 Bolt 1 4 20 Case to Cover 2400 Series 8 10 10 9 13 6 Bolt 1 4 20 Axle Support Housing 2400 Series 8 10 10 9 13 6 Bolt 1 4 20 Differential 2400 Series 7 10 9 5 13 6 Bolt 5 16 18 Case to Cover 2500 Series 180 216 15 18 20 4 24 5 Bolt 3 8 16 Differential 2500 amp 2600 Series 420 480 35 40 47 6 54 4 Bolt 1 2 13 Axle Support Housing 2500 amp 2600 Series 720 780 60 65 81 6 88 4 Screws No 10 24 Cover R A D 20 24 1 6 2 2 2 2 7 Bolts 1 4 20 Retainer Cap R A D 90 110 7 5 9 2 10 2 12 5 NOTE Onaallunits containing two jam nuts secure brake lever hold the bottom nut and torque the top nut to 100 in Ibs 11 3 Nm Differential Bolts 7 ft Ibs 9 5 Nm Drive Bolt 8 11 ft Ibs 10 9 15 0 Nm Drive Cover Screw 20 24 in lbs 2 24 3 7 Nm RIGHT ANGLE DRIVES 100 SERIES 1100 TES e 300 SERIES x om et 1200 SERIES i SX 810 SERIES 801 SERIES 900 SERIES 920 SERIES 930 SERIES in 1300 SERIES XA SPECIFICATION NUMBER o 00506 MODEL NUMBER REQUIRED REQUIRED FOR WARRANTY PEERLESS FOR WARRANTY 1 275 1374 5 13 VARIOUS STYLES OF PEERLESS 205 027C TECUMSEH dem Ma
46. 477711176 DO NOT shift on a hill or when carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury A WANNA 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 CAP SCREWS 6 The H pattern transmission described here is a 4 speed forward 1 reverse unit 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 26 SETSCREW If installed remove the neutral start switch This can be an option to the OEM NOTE Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty 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 Remove the shift lever by removing the four hex screws on the shift lever cover 3 With a 3 32 inch Allen wrench remove the set screw spring and detent ball 4 Remove the six cap screws that fasten t
47. 70251 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 SNAP RING NEUTRAL COLLAR RECESS IN KEY COLLAR SPUR GEAR SPLINE 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 SEAL BUSHING SHIFTER WASHERS THR
48. Differences in assemblies will be noted in the following servicing procedure Always use the parts list for each model to obtain the correct parts NEUTRAL GROOVE SHIFTER FORK DETENT BALL SHIFTER ROD B SHIFTER FORK NEUTRAL GROOVE DETENT BALL AND SPRING 3 Stop 3 Speed Transaxle Shifter Rod amp Fork Assy 115 SHIFTER FORK INDEXING BALL AND SPRING NEUTRAL GROOVE INDEXING BALL SHIFTER ROD B SHIFTER FORK NEUTRAL GROOVE 4 Stop 4 Speed Transaxle Shifter Rod amp Fork Assy 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 INSPECTION Replace the shifter stop if worn or damaged 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 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 750 19 1 mm 4 Replace other parts showing wear looseness cracks etc DISASSEMBLY To disassemble the shifter and fork assembly use the assembly procedure in reverse ASSEMBLY 1
49. EAR INPUT THRUST BEARING WASHER 10 Remove both the input and shifter gear and shaft assemblies along with the shifter rod and fork 11 Remove the input shaft and gear assembly 12 Remove the output shaft and gear INSPECTION AND REPAIR Axle Supports 1 Check ball bearings and bearing races for wear rust and ease of rotation Clean the interior of the support if necessary 2 Replace the oil seals in the axle supports 3 Check for cracks in the support Case and Cover 1 Check for leaks or cracks 2 Asnecessary replace needle bearings as described in Chapter 10 3 Do not replace brake shaft and shifter rod seals until the unit is reassembled HIGH RANGE BEVELED SIDE OF GEAR TEETH BEVELED SIDE OF GEAR TEETH LOW RANGE SHIFTER AND OUTPUT PINION HIGH LOW RANGE RANGE NEUTRAL GROOVE SNAP RINGS 2 SHIFTER ROD Shafts and Gears 1 Check teeth for wear pitting or breakage 2 Inspect bearing surfaces for smoothness 3 Inspect gears and shafts for out of round 4 Splines should allow a smooth fit Rotate meshing parts for a better fit if binding seems excessive SHIFTER FORK PARTIALLY REMOVED T x RANGE SNAP RINGS NEUTRAL GROOVE SHARP SIDE OUT Shifter Mechanism 1 Check spring for tension and ball for wear 2 Check shifter rod grooves for wear Be sure the sharp edge of the snap ring goes away from shifter fork 3 Inspectthe shifter fork for
50. HRUST WASHER 9 LUBRICATION Permanent Lubrication 36 oz 1065 ml of Bentonite grease Part No 788067B No acceptable substitute 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 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 When shifting gears verify the 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 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 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 i N E Ni 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 be
51. L 600 DISASSEMBLY NOTE Axles vary in length so make a sketch of which axle goes where ROLLPIN 1 Drive outthe roll pin that secures the drive pin with a suitable punch 3 Install the bevel pinions SIMULTANEOUSLY FROM OPPOSITE SIDES by rotating pinions in opposite DRIVE PIN 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 THRUST WASHERS 4 After aligning insert thrust washers behind each pinion Insert the drive pin and secure with a roll pin MODEL 800 DISASSEMBLY 1 Same as disassembly for model 600 except for additional parts on the axle N THRUST WASHERS 3 Thrust washers must be removed before attempting to remove the pinions Remove the bevel pinions 2 Remove and inspect seals bearings and washers simultaneously by rotating the gears in the opposite for wear replace if necessary direction the gears will move out of position 3 7 P 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 4 Remove snap ring bevel gear and thrust washer Slide the axle out 5 Inspectthe bushings and gears
52. L ASSEMBLY BEARING STRAP Sam DIFFERENTIAL BULL GEAR 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 100 MST SERIES DIFFERENTIAL This unit is similar to the 900 exceptit uses no bearing blocks The differential is supported by the shoulders on the ring gear CAST IRON DIFFERENTIALS USED IN TECUMSEH PEERLESS TRANSAXLES RING GEAR d AN NN HEX HEAD BOLT BEARING SURFACE 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 FOURRETAININGBOLTS SNAP RING RETAINER DIFFERENTIAL CARRIER WITH 55 THREADED BOLT HOLES SSS PINION GEAR DRIVE BLOCK DIFFERENTIAL GEAR 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 4 This illustration shows axles with snap ring 5 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
53. 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 30 IDENTIFICATION 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 3 If installed O E M option remove neutral start switch 4 Remove the allenhead setscrew the detent ball and spring DISC BRAKE LEFT OR RIGHT HAND OPTIONAL SHIFTROD NEUTRAL START SWITCH OPTIONAL BRACKET SCREWS NOTE 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 NOTE Before disassembly observe how the V notches on the flanged bushings fit into the corresponding recess in the case SHIFTER BRAKE SHAFT CASE HALF SHIFTER FAN OIL SEAL OIL SEAL FLANGED BEARING BUSHING F RETAINER FLANGED COUNTER DIFFERENTIAL FLANGED Shap ASSEMBLY NOTE The square cut black rubber O rings on the shifter brake shaft which ret
54. NDEX BALL AND SPRING LOCATION SHIFTER BRAKE QOUTPUT SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFT ROD OPTIONAL SHIFT ASSEMBLY ROD LOCATION 5 Remove the two brake bracket screws and remove brake assembly 6 Remove the grease from the unit as the parts are removed NOTE Bentonite grease may stain clothes Care should be used when handling 51 940 SERIES 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 lt 5 BEARING STRAP DIFFERENTIAL BULL GEAR gt AXLE BEVEL GEAR 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 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 l
55. ODELS PART AFFECTED IN LBS FT LBS Bolt 5 16 18 Housing 100 Series 228 264 19 22 25 8 29 9 Nut 5 16 18 Housing 100 Series 120 156 10 13 13 6 17 7 Bolt 1 4 20 Case to Cover 600 Series 84 108 7 9 9 5 12 2 Bolt 5 16 18 Axle Support Housing 600 Series 156 180 13 15 17 7 20 4 Bolt 1 4 20 Shift Lever Housing 600 Series 7 9 9 5 12 2 Bolt 1 4 20 Brake Disc 600 Series 7 9 9 5 12 2 Bolt 1 4 20 Case to Cover 800 amp 900 Series Except 820 7 5 8 3 10 2 11 3 Bolt 1 4 20 Brake Disc 800 900 amp MST Series 7 1 9 2 9 7 12 5 Bolt 5 16 18 Case to Cover 820 Series 180 216 20 4 24 5 Bolt 1 4 20 Bearing Cap 820 Series 90 100 10 2 11 3 Bolt 1 4 20 Differential 820 Series 84 120 9 5 13 6 Bolt 1 4 20 Brake Disc 820 Series 85 110 9 7 12 5 Bolt 5 16 x 18 1100 Series 180 216 15 18 20 4 24 5 Bolt 5 16 x 18 2800 Series 180 216 15 18 20 4 24 5 Bolt 1 4 20 Case to Cover 1200 Series 10 9 13 6 Bolt 1 4 20 Shift Lever Housing 1200 Series 9 5 122 Bolt 1 4 20 Differential 1200 Series 9 5 13 6 Bolt 1 4 20 Case to Cover 1300 Series 90 110 7 5 9 2 10 2 12 5 Bolt 1 4 20 Differential 1300 Series 84 120 7 10 9 5 13 6 Bolt 1 4 20 Case to Cover 1400 Series 10 9 13 6 Bolt 1 4 20 Shift Lever Housing 1400 Series 9 5 122 Bolt 1 4 20 Differential 1400 Series 9 5 13 6 Bolt 1 4 20 Case to Cover 2300 Series 96 120 10 9 13 6 Bolt 1 4 20 Shift Lever Housing 2300 Series 96 120 10 9
56. R BOLTS Through bolts holding the differential parts together The heads of these bolts must be opposite the output shaft gear except in the 2400 series This is an early check to see that the unit is being assembled correctly 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 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 EQUIPMENT The complete assembled product riding mower tractor etc which uses of the drives listed in this manual 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 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 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 brin
57. RUST WASHERS Arunning change has been made to the shift washers Many models have used the 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 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 33 FLANGED BUSHING SPROCKET SHIFTER BRAKE SPLINE FOR DISC BRAKE SQUARE FLANGED BUSHING CUT 0 RING V NOTCH THRUST NOTE The large thrust washer on the shift gear end of the shifter brake shaft does not have a chamfer on the inside diameter 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
58. TE 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 1 2 3 Install the input shaft and all the associated parts in the order shown on the input shaft breakdown Grease all four keyways insert keys into collar and keyways and slide onto the shifter brake shaft SHIFTER BRAKE SHAFT Sy TN e EET ai fa Hy Ji Es pay SHIFT COLLAR SHIFT KEYS 4 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 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 LARGE LARGER RADIUS INNER SPACE TOWARD DIAMETERS SHIFT KEYS FACE EACH OTHER d NEUTRAL SPACERS REVERSE CHAIN SPROCKET COLLARS 4 Insert the countershaft
59. UST WASHER 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 D facing the shift key opposite the brakeshaft 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 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 sour gear Next place the bronze bushing and the oil seal on the shaft the open side of the seal must face inward This completes the spur gear side of the shifter brake shaft The output side only requ
60. a beveled spline to engage 3rd or 4th gear through an additional splined shaft 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 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 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 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 SPROCKET A geared wheel designed to turn a chain drive Sprocket diameters vary and are available in different sizes for changing output ratios 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 th
61. ach unit MODEL 100 DIFFERENTIAL DISASSEMBLY 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 2 Remove four 4 locknuts bolts and the sprocket Separate the differential carrier housings PINION BEVEL GEAR DRIVE PIN 3 Remove the drive pin pinion gears and thrust washers as a unit 98 100 SERIES DIFFERENTIAL X HOUSING THRUST WASHER DRIVE PIN PINION GEARS 4 Remove the snap ring bevel gear and thrust washer Slide the axle from the differential carrier housing NOTE 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 2 Place pinion gears and thrust washers on the drive pin and insert the assembly into either differential housing carrier 3 Use oz 89 ml of bentonite grease as a lubricant 4 Assemble the differential carrier housings and sprocket with 4 bolts and locknuts NOTE 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 If no gasket is present seal the housing with Loctite 598 part number 788093 using a 1 8 3 18 mm bead MODE
62. ailure which could result in equipment damage death or serious injury 915 SERIES 940 SERIES TRANSAXLES Ss MSN SHIFTERIBRAKE Rh Sb 4 GS LUBRICATION Permanent Lubrication 10 oz 296 ml of Bentonite grease Part No 788067C ROUNDED SIDE TOWARDS KEYS SHIFTING WASHERS NOTE SOME 915 MODELS WILL USE STYLE INPUT CONSULT THE MECHANICS HANDBOOK F R PROPER ASSEMBLY THIS IS A GUIDE ONLY 0 ONLY 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 TWEET 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 WARNING VI WYN Ta DO NOT shift on a hill or when Carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury A 77111127 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
63. ain the Bentonite grease in the case 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 NOTE Remove the Bentonite grease from all parts and case halves as they are removed FLANGED BUSHING FLANGED BUSHING i OUTPUT FLAT WASHER SQUARE FLANGED PINION CUTSEALINEACHEND SPUR BUSHING FLAT WASHER OF OUTPUT PINION GEARS 8 Remove the needle bearing closed end flat washers 2 output gear and output pinion and 3 square cut 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 FLANGED SQUARE CUT FLANGED BUSHING O RING BUSHING SHIFTER BRAKE SHAFT R Ss 5 9 SPUR GEAR SPROCKET MN R N AM AN POM 2 V SQUARE CUT COUNTERSHAFT O RING SPROCKET COLLAR 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 SPUR GEARS SPLINE FOR CHAIN SPROCKET GEAR 1 ri D 0 1 5 55 Ss If fi i SPROCKET THRUST WASHER FLANGED BUSHING BEVEL GEAR 10 Remove the sprocket bevel gear
64. aining edge The parts are to be replaced as an assembly DRIVE BLOCK WASHER 6 Remove the snap ring and the thrust washer Separate the bevel gear and the differential carrier from the axle INSPECTION 1 See Chapter 22 on Bearing and Bushing Service 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 3 Examine the drive pinions drive pins and drive blocks for wear and damage Replace the pinion or the drive pin if excessively worn 101 HOLES THREADED IN ONLY ONE DIFFERENTIAL SNAP RING DIFFERENTIAL CARRIER RING GEAR REMOVED WASHER 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 5 Examine the internal bearing diameter of the differential carriers SERRATED AXLE END ROLLER THRUST BEARING WITH ONE THRUST WASHER DIFFERENTIAL CARRIER 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 REASSEMBLY 1 Oilall 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 te
65. ake 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 INPUT SHAFT CENTER PLATE SHIFT LEVER HOUSING DISC BRAKE 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 LEFT AXLE DOWEL PIN 1 AXLE HOUSING 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 sral PROTECTOR SHIFTER DIFFERENTIAL ASSEMBLY 5 CENTER ty 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 NOTE 4 Use a seal protector on the axle shaft and lift off the transaxle cover assembly Because this seal Examine the assembly carefully if no service is is the single lip style it may be reused if care is required keep the assembly together as a unit If service taken to see that it isn t cut or scratched is necessary refer to Chapter 21 on s
66. als are identified by external ribs that hold the seal in place and prevent leakage DO NOT put sealant in the seallbearing pockets with this new type of seal 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 10 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 11 Install the cover screws and torque them to 90 100 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 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 12 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 as
67. and washers have been added in their proper sequence OUTPUT GEAR LARGE BEVEL GEAR THIN SHIFTING WASHER 4 Onthe 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 input the bevel will be outward or away from the keys 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 ofthe shaft to complete the assembly of the shifter brake shaft REVERSE GEAR COLLAR LOCATION FOR SPACER SOME MODELS 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 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 spac
68. ansaxle 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 Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty OPTIONAL INPUT SHIFT ROD INPUT SHAFT e x INDEX BALL SPRING AND SET SCREW BRAKE BRACKET SCREWS BRAKE CAN BE ON RIGHT OR ON LEFT SIDE DISASSEMBLY OF TRANSMISSION Clean outside surface of transmission Position shift lever in neutral as indicated by the shift pattern NEUTRAL START SWITCH LOCATION OPTIONAL 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 3 Remove cover Remove shifter assembly includes shift rod and shifter fan from transmission by lifting shaft out of case 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 5 OUTPUT PINION AND SHAFT Remove sleeved needle bearings Remove the large thrust washers and large output gear The output pinion gear is machined directly onto
69. ar 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 800 series shifter brake shaft 930 Series This unit has 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 1200 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 2300 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 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
70. ardown 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 3 Torque the four hex head bolts to 7 ft Ibs 5 2 Nm 102 TESTING 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 DUO TRAK Illinois tool works DIFFERENTIAL OPERATION 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 DISASSEMBLY INSPECTION AND REPAIR Parts breakdown will be found on the next page Remove the four throug
71. aring blocks and is retained by the case and cover This unit contains an aluminum tag at location A or B showing the model number COVER CASE HEX SCREWS INPUT suiFT SHAFT 42 DISASSEMBLY OF TRANSAXLE 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 2 Remove Allen head setscrew spring and detent ball from the transmission cover and six cap screws that fasten the cover to the case 3 Remove cover Remove shifter assembly includes shift rod and shifter fan from transaxle by lifting shaft out of case 4 Remove two brake bracket screws and remove brake assembly NOTE 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 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 COUNTERSHAFT OUTPUT SHAFT SHIFTER BRAKE SHAFT 6 To disassemble the countershaft output pinion and shaft assembly simply pull apart COUNTERSHAFT 7 Remove
72. aring in the cage housing does not have end play and the parts should spin freely 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 Ibs 22 6 Nm To install seals use a 1 seal protector Position seals so that they are installed 100 2 5 mm below flush LUBRICATION After assembly fill with 1 pt 473 ml E P 90 gear oil 1100 SERIES DRIVE RACE TAPPERED N SPACER Ne 09 5 SNAP RING 1 r SNAP RING TAPPERED BEARIN CRUSH RACE E gt SNAP RING RACE amp TAPPERED BEARING LUBRICATION Qil Bath SMAP RING 16 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 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 KEY SPRING HEIGHT
73. arts EXCEPT BEARINGS 3 Check bearings for smooth rotation then lubricate gt Remove all burrs and scratches from shafts with fine file or stone Check housing for cracks or pulled metal Replace all snap rings Replace all oil seals o 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 108 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 ALWAYS REPLACE OIL SEALS 11 Install a new oil seal using a seal protector sleeve part 670293 and driver until the seal is flush with the housing POSITION OIL SEAL THEN USE SEAL DRIVER TO SEAT SEAL SQUARELY TO THE PROPER DEPTH SIZE SEAL PROTECTOR 12 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 13 Align the shaft and insert a ball bearing on each bearing surface by hand 14 Install new seals in the retainer caps using a driver 15 Using seal protector 670293 over the shaft serrated ends install new gaskets and the bearing cap Tighten
74. ashers bevel gear and snap ring SNAP RING GROOVE vs Aem TES EJ BS 1 y 3 Ap SNAP RING 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 REVERSE SHIFT GEAR GEARS SHIFT WASHERS NEUTRAL SPACER SHIFTING WASHER eo CUT OUT SIDE FLAT SIDE NOTE 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 Then place a shifting washer onto the shaft with the rounded edge towards the shifting keys Continue this procedure until all the gears
75. ce chain becomes wedged UNIT IS NOISY Gearing is overly noisy chatter etc Check oil grease level Metallic pieces or other foreign objects in unit Remove bits of broken metal loose washers etc Worn gears Remove and replace with new gears Worn bearings mainly input shaft ball bearing Replace the bearing in question check the belt tension CHAPTER 2 300 SERIES GENERAL INFORMATION 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 Only the external parts listed below in the illustration are available from your normal source of supply Basic Troubleshooting Should a drive problem exist check the following 1 Cable adjustment Belt tension and mechanism Drive lever operation Check for worn or glazed belt or damaged pulley Should the unit still not operate correctly replacement will be required Externally Serviceable Parts Retaining Ring Drive Pulley Tension Spring Retaining Ring or Push Nut Drive Arm SERVICEABLE PARTS ID LOCATION CHAPTER 3 600 SERIES TRANSAXLES A WARNING 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 s
76. ck fork assembly together INSPECTION AND REPAIR Axle Supports 1 Check the roller bearings on the axles Clean and Fe move any must 3 Check differential lock collar for fork or pin wear 2 axe supports anid inspect 4 Check ball bearings for ease of rotation Replace Case and Cover any parts if necessary 1 Check for leaks or cracks ASSEMBLY 2 Replace all oil seals As necessary replace needle Install parts reversing the disassembly procedure Be bearings as described in Chapter 22 on bearing careful of the following PRESS 1 Afterthe shifter rod is positioned install the detent 3 Donotreplace brake shaft seal brake shaft shifter ball spring and bolt Turn the set bolt inward dual rod and shifter differential lock seals until the unit speed until it contacts the case is reassembled 2 Besurethatthrust washers and spacers are between Shafts and Gears every shaft and case and cover 1 Checkteeth for wear pitting or breakage 3 Threads of the differential bolts must be coated surfaces with standard stud Loctite The bolt heads are up 9 when installed Refer to Chaper 18 on differentials 3 Inspect gears and shafts for an out of round condition 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 s
77. d 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 fitis loose itis 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 66 IDENTIFICATION 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 IDENTIFICATION TAG STEPS TO TAKE BEFORE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position SQUARE CUT O RING REMOVE FILL PLUG AND PUSH NUT 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 4 Remove the neutral start switch if installed O E M option 5 Remove the push nut if equipped and square cut O ring from the top of the shift fork shaft
78. do so could result in equipment damage death or serious injury GENERAL INFORMATION The 700 Series in line shift transmission is available in 2 3 4 or 5 speeds forward depending on equipment manufacturer s specifications 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 NEUTRAL START PROVISION OUTPUT DISC BRAKE eS 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 NEUTRAL START SWITCH OUTPUT SPROCKET DISC BRAKE DISASSEMBLY OF TRANSMISSION 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 2 Remove setscrew spring and index ball from the transmission cover and six cap screws that fasten the cover to the case 3 Remove cover Remove shifter assembly includes shafts pins and fan from transmission by lifting shaft out of case SPRING SETSCREW CAP SCREWS 4 Remove gear and shaft assemblies from the case lifting the two shaft assemblies together taking care not to separate th
79. e amp 4 Chamfer on inside THRUST WASHER Su diameter of washers _ BUSHING gt gt toy 22 _ THRUST WASHER 2 BUSHING RUBBER WASHER P d REVERSE GEAR Thick coller toad Ene sc ai Coy 0 RING us C B THRUST WASHER SPUR GEARS A LL THRUST WASHER _ BUSHING LUBRICATION Permanent Lubrication 26 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 A WARNING When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury A WARNING VMN NOT shift on a hill or when EI carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury WWW 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
80. e bevel spur gear install sprocket onto the serration and install chain Install all four 4 thrust washers 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 i in transmission case the cover won t sit squarely on the case 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 Ibs 10 2 12 5 Nm 28 TORQUE SCREWS 70 90 IN LBS 7 93 10 2 Nm TABS IN SHIFTER PLATES 2 6 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 7 Checkfor 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 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
81. e drive chain and sprocket relationship Take note that the fat side of the sprockets must face the tips of the keys SHIFTER ASSEMBLY SHIFTER FAN mum SHIFTER PINS 21 5 Remove the one piece bevel spur combination gear and the remaining splined spur gears from the countershaft 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 A CAUTION Use approved safety procedures with equipment when handling shifter brakeshaft parts These parts have extremely sharp edges Inadequate safety precautions could result in equipment damage and serious injury FAT SIDE MUST FACE THE KEY TIPS REMOVE BEARING AND SPROCKET BUSHING SHOULDER THICKEST THRUST COLLAR 7 Remove the snap ring from the input shaft remove bevel gear and pull shaft through case 8 Input shaft needle bearings should be installed flush to 005 127 mm below bearing bore surfaces from inside and outside the case SNAP RING BEVEL GEAR O RING THRUST WASHER SNAP RING 22 INSPECTION AND REPAIR Remove grease with rags and cleaning solvent and replace worn or damaged parts ASSEMBLY OF THE 700 SERIES IN LINE TRANSMISSION 1 Install and secure the input shaft and bevel
82. e grease around the gearing and reinstall the cover to the case Torque cap screws 90 110 in Ibs 10 2 12 5 Nm SHIFTER ASSEMBLY SHIFTER FAN ES aoe ael 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 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 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 A WARNING Follow recommended guidelines 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 24 700 SERIES TRANSMISSION MODEL end SERIAL HERE eet BALL SARA aud SET SCREW _
83. e 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 Ifthe 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 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 5 Checkthe 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 6 Hard shifting with the engine shut off can be caused by bent or binding shift lever or linkage shift linkage out of adjustment corrosion in the transaxle or transmission
84. e keys Pull the neutral spacer and reverse sprocket up against the snap ring on the shifter brake shaft WASHER amp SPUR GEAR EN 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 NOTE As all the gears are placed back into the assembly each should be packed with Bentonite grease SPUR GEARS SHIFT GEARS SHIFTING SHIFT WASHERS WASHER 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 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 Itis not only important that gears match up according to diameter but also to thickness THRUST WASHER SPACER TE BUSHING O RING WASHER 6 Place the spacer on the countershaft next to the re
85. e nud k a g 1 7 ii Pra 08 e 1 E 8i gt lt gt 1 l 9 i I OUTPUT GEAR J Pod AND PINION g amp eS bs ER 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 A W X It is recommended that you take GENE 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 J Use approved safety procedures MITT 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 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 The differential assemblies for the 820 1200 1300 2300 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 e
86. e 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 Grasp the axle bevel gears between your thumb and fingers holding together while lifting differential from case 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 COUNTERSHAFT ASSEMBLY OUTPUT SHAFT ASSEMBLY 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 mmi Bal m d UU M 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 NEEDLE BEARING FLUSH WITH SQUARE CUT NEEDLE BEARINGS 135 3 43 mm 150 3 81 mm THRUST WASHER BEVEL GEAR RETAINING RING NOTE Needle bearings are lubricated with
87. e 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 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 53 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 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 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 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 th
88. eal 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 After the unit is assembled install the brake shaft oil seal using a seal protector installer 7 Installthe shifter rod oil seal using the seal protector 670206 and driver 670211 8 Install the locking differential shifter rod oil seal using the seal protector 670206 and installer 670211 9 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 cmd Se ea 1 INPUT GEAR OUTPUT GEAR ANO PINION LUBRICATION Part No 730229B Refer to O E M manual for type of lubrication se ee eye ee ee oe 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 INPUT SHAFT 4 BEVEL GEAR D o 2 7 bea 2 GEAR CLUSTER 1 7 9 l dg ATA 9 Q t 2 7 1 f e SHIFTER SHAFT EIE j 7 d 1 1 47 2 9
89. eedle 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 Dependent on whether the brake is on the right or the left will determine which end uses a capped sleeved needle bearing 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 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 NEEDLE BEARING BEARING SLEEVE O RING OUTPUT GEAR 0 RING BEARING SLEEVE OUTPUT WASHER NEEDLE BEARING THRUST WASHER 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 10 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 SHIFTER BALL BEARING DIFFERENTIAL 40 11 Guide c
90. either gasket eliminator Loctite 515 part number 510334 or silicone RTV Loctite 598 part number 788093 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 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 1 0 of the splined brake disc The brake pads and brake disc must be free of grease and oil Install 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 Follow recommended guidelines 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 35 The above illustration is supplied as a general assembly guide your model may be different based on 800 801 SERIES TRANSAXLES 1 BALL SPRING ard SET SCREW ifur pruper selling ure SHAFT ESS d d i T BRAKE SHAFT INPUT GEAR ET ka T lt 9 DUTRUT GEAR 4 e
91. em 7 Install the shifter assembly bearing strap and reverse idler assembly if applicable Pack the transaxle with the remaining Bentonite grease 10 ounces 296 ml total Replace the spring set screw and the detent ball 54 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 8 Guide the cover over the shift rod and position onto the case Install the cover cap screws and torque 90 100 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 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 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 manual for correct brake adjustment Failure to do so could result in excessive brake pad wear and brake f
92. ential assembly begins with the shortest axle SHIFTER FAN 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 10 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 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 12 Reinstall the ball spring and set screw on the models that have them The setting for the screw is flush to the cover Check for binding by turning the input shaft APPLY LUBRIPLATE 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 1 0 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 Follow recommended guidelines in equipment manufacturer s manual for correc
93. er removing grease with rags and cleaning solvent to determine which parts need replacement ASSEMBLY OF 700H SERIES TRANSMISSION OUTPUT AND BRAKE SHAFT Assembly is the same as the 700 series in line transmission except for an additional collar and spacer SHOULDER 45 CHAMFER THRUST WASHER SEPARATES GEAR FROM BEARING CUT OUT SIDE OF GEAR MUST FACE OUTBOARD END OF SHAFT FLAT SIDE OF GEAR MUST FACE SHOULDER ON SHAFT 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 BRAKE CHAIN SPROCKET DISC OUTPUT COLLAR SPROCKET Ss OUTPUT AND BRAKE SHAFT MOT AU ULT i cna it 1 BUSHING rm IL 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 BEVEL SPUR GEAR SPACER 2 Assemble the countershaft and gears as shown above remembering the spacer is in the 4th gear position 27 COLLAR MUST FACE BEVEL SPUR GEAR COUNTERSHAFT REMOVE BEARING BEVEL SPUR GEAR AND SPROCKET SPACER BUSHING THRUST WASHER THRUST WASHER SPACER THRUST WASHER SHOULDER CHAIN 3 With the collar on the countershaft sprocket facing th
94. erious injury A WARNING When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury 714771277176 DO NOT shift on a hill or when carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury A 77121111721 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 GENERAL INFORMATION There are two types of 600 Series transaxles One is the 600 standard series and the other is the 601 001 002 003 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 600 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 TRANSAXLE DISASSEMBLY NEUTRAL POSITION 1 Clean the outside surface of the transaxle in an area away from where service will t
95. ete 109 113 CHAPTER 21 Shifting Assembly 5 ute RR LU ERES 114 116 Shift Key Quick Reference Guide ae I at aen cu 117 CHAPTER 22 Bearing and Bushing Service ie Repeat dert orte deque a 118 119 CHAPTER 23 VST Tro bleshootihg ease 120 121 Tecumseh Products Company 2002 CHAPTER 1 MODEL OVERVIEW AND TERMS USED TECUMSEH TRANSMISSIONS UNITS 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 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 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 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 600 Series The 600 series i
96. fere with removal of the unit in anyway remove it before unit removal These can easily be bend out of shape 6 Remove all attached hardware holding the Tecumseh Transmission unit to the equipment on the case cover axle supports brake and shifter 7 Remove the unit from the equipment Preparing for disassembly of a unit 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 3 Remove the shift housing and drain the lubricant from unit Observe the old lubricant to see if metal particles are present 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 5 Check the model and specification number and remember to have the exploded parts diagram accessible during disassembly 6 Haveon hand seal protectors drivers shop cloths appropriate tools and this technicians handbook while servicing a unit 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 GUIDELINES TO REMEMBER 1 Other than leaking seals gaskets and rings leakage can
97. for wear and replace when necessary REASSEMBLY OF DIFFERENTIAL ASSEMBLY 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 differential to prevent dirt entry snap ring in the groove on the shaft 99 OLD STYLE SEAL NEW STYLE i HEAVY DUTY SEALED BALL BEARING 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 must have the seal to the outside of the bearing When bearing style 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 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 MODELS 900 910 915 920 and 930 DIFFERENTIAL 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 DIFFERENTIA
98. g 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 SNAP RING STYLE Use a snap ring pliers for removing the snap ring loosen the vise and disassemble the pieces 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 the ball position so equal lengths protrude from both sides of the ball 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 Prior to reassembly be sure the bends in the shift lever correspond to the mounting on the vehicle REASSEMBLY 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 HANDLE END SHIFT LEVER 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 Always use new gaskets between the shift lever housing and the transaxle SHIFTING ASSEMBLY GENERAL 1
99. gear in the case Review paragraphs 7 amp 8 and reverse the order 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 shafts and gears Tecumseh part number 788067C CHAMFERED SHIFT WASHERS Many older models have a thrust washer with a 45 chamfer on the inside 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 COLLAR OUTPUT AND BRAKE SHAFT SHOULDER SEPARATES GEAR FROM BEARING CUT OUT SIDE OF GEAR MUST FACE OUTBOARD END OF SHAFT FLAT SIDE OF GEAR MUST FACE SHOULDER ON SHAFT 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
100. ght rests on the input shaft or differential but keeping the case rigid 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 3 Oilseals have a double lip so seal sleeves do not offer much protection during removal Upon reassembly new seals should be used 4 Tap dowel pins into the case and remove socket head cap screws OUTPUT GEAR WASHER SPACER 5 Lift the cover off of the case Discard the gasket Remove output gear and shaft 6 Remove the shifting assembly as one unit REVERSE IDLER GEAR SHAFT AND SPACER INPUT SHAFT AND GEAR GEAR CLUSTER ASSEMBLY 8 Lift out the three gear cluster INPUT SHAFT 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 INSPECTION AND REPAIR 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 2 Install the differential as
101. gs power to the unit LIMITED SLIP DIFFERENTIAL See DUO 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 NEUTRAL SPACER A single or split collar between forward and reverse gears that the shift keys engage into when the unit is in neutral 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 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 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 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 depend
102. gum NM 17 Rl ee _ COUNTERSHAFT DIFFERENTIAL gt 425 are uL i LUBRICATION Permanent Lubrication 30 oz 887 ml for 800 Series 36 oz 1065 ml for 801 Series Bentonite grease Part No 788067C HUMES HERE manufacturers requirements 36 Tul turn aim cea fram ROUNDED SIDE TOWARDS KEYS SHIFTING WASHERS WASHERS 7 i hemder an inde 7 must Inga keya THRUST WASHFA BUSHING es BR WASHER Bg P _BUSHINE Bey 820 SERIES TRANSMISSIONS is recommended that you take E 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 mre When shifting gears verify the FEF clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury J DO NOT shift on a hill or when 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 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 The 820 series is similar to the 920 series tr
103. h 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 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 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 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 Ibs 5 2 13 6 Nm BODY CORES RING GEAR M Se o8 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 opti
104. he Loctite Silicone RTV 598 Tecumseh Part number 788093 15 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 Check for binding by turning the input shaft APPLY LUBRIPLATE 16 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 1 0 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 Follow recommended guidelines 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 45 900 SERIES TRANSAXLE DEDENT BALL 5 SPRING ani WASHER 9 For proper setting turn screw full turn into cover from flush 1 ROUNDED SIDE INPUT SHAFT TOWARD KEYS NG 9t E gt an KEYS 2 2 9 INPUT GEAR TPUT GEAR SHAFT AND PINION SS 2 L REVERSE GEAR Thick collar toward gears 28 6G NEUTRAL SPACER C LARGE BUSHING wasters THRUST WASHER
105. he cover to the case then remove the cover HUB MUST FACE COUNTERSHAFT SPUR GEARS BEVEL SPUR GEAR BEVEL SPUR GEAR BUSHING HERE SHOULDER WASHER M COLLAR 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 THICKEST THRUST WASHER 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 BEVEL SPUR GEAR A SPACER Disassembly of the 700 series H shift pattern includes a spacer OUTPUT BRAKE CHAIN SPROCKET DISC SPROCKET OUTPUT AND BUSHING BRAKE SHAFT Disassembly of the 700 series shift pattern includes a second collar and a spacer SNAP RING BEVEL GEAR THRUST WASHER INSTALL BEARINGS FLUSH TO 005 127 mm BELOW ASE SURFACE NEEDLE BEARINGS O RING SNAP RING 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 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 INSPECTION AND REPAIR Examine all parts aft
106. hifting assemblies DIFFERENTIAL ASSEMBLY SCREW FASTENERS 5 To remove the differential assembly it may be necessary to replace two or three screws that 8 Remove the reverse idler shaft spacer and gear hold the center plate assembly down Pull assembly straight up If tight tap on lower axle 9 Remove the cluster gear sub assembly and thrust with a soft mallet CAUTION DO NOT USE washer STEEL HAMMER Refer to the chapter on differential assembly service Remove the gear on top of the shifter shaft CENTER PLATE ASSEMBLY BEVELED EDGE THREE SENS 6 Afterremoving the center plate assembly screws remove center plate and discard the gasket LONGER KEYWAY pa DIFFERENTIAL CY EUM ASSEMBLY GERE 55 SHORT KEYWAY SMALL GEAR OLD STYLE Lone MARGE GEAR SMALL SPACER GEAR 10 Cluster Gear Sub Assembly 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 b The small 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 c Key edge ends must align with shaft ends THRUST BEARING IDLER GEAR THRUST WASHERS 11 Remove the idler gear thrust washers and thrust bearing 16 12 Remove the input shaft oil seal to allow access to the snap ring Remove snap ring and inpu
107. how 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 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 02 236 ml capacity 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
108. hten the eight socket head cap screws Torque screws to 10 ft lbs Unit can now be placed flat on the work bench 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 OIL SEAL RETAINER THRUST BEARING ASSEMBLY 15 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 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 Ibs 17 6 Nm 17 Install the shift lever housing and new gasket INTERNAL QUAD RING SEAL USED ROLL OR DOWEL PIN SCREWS TORQUE TO 10 FT LBS 13 6 Nm TESTING AND LUBRICATION 1 Fortesting refer to Chapter 1 page 6 2 For proper lubrication type and amount refer to Chapter 1 83 2300 SERIES TRANSAXLES Pale qa MODEL and SERIAL ai S ox id po X 99 w 3rd and 4th diim 2 RECO 1st 2nd and REVERSE SHIFTING GEAR ee 295 S proe Sun T SHA OP M ae NS 6 2 DUNT Lun d SA qum e 1 s Q ue 2d s SEALED e LUBRICATION Oil Bath 64 oz 1892 ml S A E E P 90 oil to be filled through shift lever opening Part No 730229B The above illustration
109. ial 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 A WARNING When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury 77977717176 DO NOT shift on a hill or when carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury A 771171777 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 GENERAL INFORMATION NOTE 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 NEUTRAL START SWITCH OPTIONAL SETSCREW INPUT 0 E M OPTION 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
110. ics oil can These 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 Reinstall the plug by lubricating it with a silicon spray lubricant An installation tool can be made by using one of the following procedures 6 152 mm 20 508 mm ROUNDED END _ 3s 76 mm FILL PLUG PUSHER TOOL 3 16 4 76 mm ROD 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 LARGE FENDER WASHER STD NO 10 NUT NO 10 SCREW BOLT 2 50 mm LONG 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 30 bit works well also 71 CHAPTER 12 1200 SERIES THREE SPEED TRANSAXLES H SHIFT PATTERN 3 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 772777777 When shifting gears verify the 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
111. ing 74 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 CHAPTER 13 HYDROSTATIC GEAR REDUCTION DIFFERENTIALS 1300 SERIES TIT 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 Use approved safety procedures D 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 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 Legend for the 1300 1 Oil Seal 8 Axle 2 Thrust Washer 9 Axle Support 3 Brakeshaft 10 Bushing 4 Needle Bearing 11 Cover 5 Output Gear 12 Differential Gear 6 Output Shaft 13 Case 7 Spacer 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
112. ing upon input speed 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 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 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 SEAL A material which prevents lubricant from leaking 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 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 SHIFT KEY One of either two or four
113. 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 Ex zm i T LARGE INPUT s BEVEL GEAR WASHER NOTE 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 SHIFT GEARS SHIFT SPUR GEARS SHIFTING WASHER CUT OUT SIDE FLAT 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 to
114. ires the output spur gear washer and bushing RETAINING CLIP 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 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 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 DIFFERENTIAL ASSEMBLY Toreassemble 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
115. is supplied as a general assembly guide your model may be different based on manufacturers requirements 84 CHAPTER 15 2400 SERIES HYDRO POWERED TRANSAXLES F It is recommended that you take c 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 Use approved safety procedures ITE 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 2400 Series transaxle is a gear reduction unit which is powered by a hydrostatic pump SEPARATING AND COMBINING THE HYDROSTATIC PUMP AND THE 2400 SERIES TRANSAXLE The two parts gear reduction unit and pump should be removed from the vehicle together 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 COAT INSIDE OF COLLAR MOUNTING SCREWS 3 WITH E P LITHIUM GREASE For service to the hydrostatic pump it must be returned to the dealer who sold the vehicle for his service
116. l the input shaft in the case Use a soft mallet to seatthe shaft and gear completely Often binding in the assembled unit can be traced to a partially installed input shaft SHIFTER ROD SHIFT LEVER SOCKETS OPENING 1 32 794 mm THICK 1 25 4 mm 1 0 THRUST WASHER UNDER IDLER BRAKE SHAFT IDLER GEAR CHAMFERED SIDE UP AWAY FROM BEARING 2 Center one 1 32 794 mm thick by 1 25 4 mm 1 0 thrust washer on the cover brake shaft needle bearing then install the brake shaft and gear with the chamfer side away from the cover 1 16 1 59 mm THICK 15 16 23 8 mm I D THRUST WASHER OUTPUT SHAFT AND GEAR OUTPUT SHAFT BEARING 3 Install the output shaft and gear after centering a 1 16 1 59 thick by 15 16 23 8 mm I D thrust washer on each end of the shaft 81 4 5 AXLE AND DIFFERENTIAL OUTPUT GEAR ASSEMBLY AND SHAFT FOUR HEX BOLTS HEADS BEARING BRAKE SHAFT 2 GEAR CLUSTER Insert the differential assembly into the cover Note that the four bolt heads should be facing away from the output gear Install the two gear cluster and spacer on the brake shaft 1 32 794 mm THICK 7 8 19 mm 1 0 THRUST a WASHER IN PLACE ON gt BEARING SQUEEZE SHIFTER RODS TO HOLD SHIFTER ASSEMBLY TOGETHER 6 8 82 TWO GEAR CLUSTER AND SPACER SPUR GEAR Install a 1 16 1 59 mm thick by 3 4 19 mm D thrust washer gear and low gear idler shaft in the
117. le 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 IDENTIFICATION This unit contains an aluminum tag showing the model number COVER CASE HEX SCREWS IS BRAKE BRACKET SCREWS DISASSEMBLY OF TRANSAXLE 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 Allen head setscrew spring and detent ball Remove the cap screws that fasten the cover to the case 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 SHIFTER BRAKE SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFTER ASSEMBLY LOCATION 4 Remove the ring from the top of the shifter rod 5 Remove the two brake bracket screws and remove brake assembly 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
118. luster Gear 670204 Idler Gear 670210 Axle Housing 670204 Reverse Idler Bearing must be flush with top of case Secure with Loctite 600 SERIES TRANSAXLES SHIFTER SE x qu ats d ou x d ana GEAR i NW ULER LATUS um et Lu SHAFT b AND GEAR tat amp REVERSE SHIFTER GEAR EA WF REVERSE IDLER GEAR LUBRICATION Oil Bath 24 oz 710 ml S A E E P 90 Oil 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 A WARNING 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 When shifting gears verify the clutch is operated Failure to do so may cause premature transmission failure which could result in death or serious injury 71477717176 DO NOT shift on a hill or when carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury A WARNING 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
119. 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 90 from case cover parting line is 90 Neutral Parting Line DIRECTION CONTROL SHAFT DIRECTION CONTROL LEVER POCKET RULE PUSH NUT FOR OIL CHECK SQUARE CUT 0 RING DIFFERENTIAL DISCONNECT HOOKUP 3 82 5 mm 3 88 9 m EXPANSION BELLOW S CHECK COLD FOR CORRECT DEPTH MODEL and SERIAL NUMBERS HERE 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
120. 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 SHIFT KEYWAY One of either two or four slots in the shifter brake shaft for the shift keys to slide through for gear selection 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 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 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 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 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
121. n replacement new seals should be used INPUT SHAFT BE SURE SEAL IS REMOVED 1 32 794 mm THRUST WASHER 3 GEAR CLUSTER BRAKE SHAFT DOWEL PIN DN 7 Remove thrust washer and three gear cluster from the brake shaft noting whether the cluster has a sloppy fit 5 Tap dowel pins into the cover and remove the socket NOTE head cap screws 2 service the cluster bushings refer to Chapter 22 on bearing and bushing service 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 PATA TID a 1 1 2 TO 2 TURN CW F 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 REVERSE IDLER GEAR AND SHAFT gears then lift it free of the differential 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 SHIFTING ASSEMBLY 10 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
122. nit should have been drained of lubrication be aware that removal of the axle support will allow trapped oil to spill NOTE An oil supply is blocked in the hydrostatic pump when not running so upon reassembly hydrostatic charging is not necessary NOTE 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 INPUT DRIVEN BEVEL GEAR SUPPORT 3 Clean all exterior surfaces of the transaxle 4 Remove the axle supports If supports are different or if there is a chance for confused reassembly scribe alignment marks 0 RING SEAL TIMKEN THRUST ROLLER BEARING 4 5 Remove and discard square O ring seal 6 Ifthetapered 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 THRUST OR TABBED AXLE AND DIFFERENTIAL ASSEMBLY OUTPUT SHAFT AND GEAR SHIFT ROD SNAP RING FROM LARGE GEAR LOW RANGE DRIVEN GEAR HIGH RANGE DRIVEN GEAR 8 Toremove the inside components first remove the differential and then thrust washers DETENT BALL SPRING AND SETSCREW 9 Toremove the shifter rod and fork the set screw spring and detent ball should be removed from the outside of the case INPUT THRUST WASHERS SHAFT Shown Assembled HIGH RANGE TRANSMISSION G
123. ntical neutral collar halves These can be installed in either direction 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 NOTE As all the gears are placed back onto the assembly each should be packed with bentonite grease BEVEL GEAR __ COUNTERSHAFT SHIFTING WASHER CUT OUT SIDE FLAT SIDE 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 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 Itis not only important that gears match up according to diameter but also to thickness 58 SPACER SPUR GEAR O RING 6 Place the spacer on the countershaft next to the reverse sprocket Then place a thrust washer on
124. nufactured on the 275th Day USED 205 027C8194A0048 Manufactured 11991 D O M DATE OF MANUFACTURE ORIGINAL SERIAL NUMBER SPECIFICATION NUMBER MODEL NUMBER REQUIRED REQUIRED FOR WARRANTY MODEL NUMBER REQUIRED SPECIFICATION NUMBER SE FOR WARRANTY REQUIRED FOR WARRANTY MST 206 502A TE M ERIAL NO FG Bu s 6304400013 E ST 205 1020C MODEL SPE TOIT D O M 7070A 0005 D O M DATE OF MANUFACTURE D O M DATE OF MANUFACTURE ORIGINAL SERIAL NUMBER ORIGINAL SERIAL NUMBER PEERLESS PEERLESS 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 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 po
125. ocated against the thrust of the countershaft reverse gear SHIFTER BRAKE OUTPUT SHAFT ASSEMBLY REVERSE IDLER ASSEMBLY COUNTERSHAFT ASSEMBLY 52 9 Asthese 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 10 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 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 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 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT NEEDLE BEARINGS C7 3 81 mm THRUST WASHER BEVEL GEAR RETAINING RING REASSEMBLY 1 Apply grease between the bearings in the cover and install the input shaft square cut seal thrust w
126. occur due to a cracked case or cover flats on shafts porosity rarely if ever and worn bushings and shafts 2 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 3 Some seals have a Redicoat sealant applied while others may need a thin coat of RTV silicone to the outer shell upon installation 4 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 usedto clear keyways splines or other machined sharp edges on the shafts TORQUE VALUE TROUBLESHOOTING GUIDELINES ALWAYS torque all fasteners to the appropriate value as listed in Chapter 1 page 9 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 A cross tightening sequence to half the torque then finally to full torque value is a recommended procedure to prevent comebacks repair returns 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 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 follo
127. odisassemble 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 aretaining 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 67 SPACER 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 NEEDLE BEARING FLUSH WITH HOUSING OIL SEAL NEEDLE BEARINGS BEVEL GEAR 701777450 3 81 mm THRUST WASHER RETAINING RING 10 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 11 After clean up of all parts a complete inspection 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 68 REASSEMBLY The tool part number 6
128. 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 EQUIPMENT MOUNTING 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 REMOVE MOUNTING SCREWS 4 HYDROSTATIC UNIT 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 HYDROSTATIC UNIT MOUNTING HOLES 4 After removing the hydrostatic unit inspect the surfaces and the gears from outside the unit 75 5 Remove the lockscrews and tap the dowel pins out of the cover Lift off the cover and discard the gasket 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 NOTE No thrust washer is located between the output shaft and the case 8 To service the differential refer to Chapter 18 on differentials 9 To service bearings refer to Chapter 22 on bearing service 10 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
129. on 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 1 0 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 Ibs 10 2 11 3 Nm The brake and linkages may vary A WARNING Follow recommended guidelines 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 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 IDLER GEAR 2 Theinput shaft only has one thrust washer instead of a thrust bearing and two thrust washers 3 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 600 SERIES BEARING TOOLS PART LOCATION TOOL REMOVE amp REPLACE BEARING SIZER Brake Shaft 670210 27 needles Axle 670204 Input Shaft 670207A Center Plate 670205 Brake Shaft 670213 30 needles Differential 670204 C
130. on by mounting a gear at the top or bottom of the shaft 1 2 12 7 mm TO 3 4 19 1 mm DIAMETER BOLT OUTPUT SHAFT BALL BEARING LARGE WASHER TO REST ON OUTER BEARING B MACHINE BOLT APPROXIMATELY 4 10 cm LONG METAL PLATE TO PROTECT LOWER 9 BEARING BEVEL GEAR 4 Ifthe driven bevel gear is on the bottom remove the snap ring on the output shaft and pull out the output shaft 5 Remove the output shaft bearing by using a large machine bolt washer and nut SNAP RING OUTPUT SHAFT AND BEARING 6 Theinput shaft bearing input shaft and bevel gear may now be driven out of the housing Press the bearing into housing to remove 7 Thetop 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 MOWER BLADE APPLY SMALL AMOUNT OF GREASE BETWEEN NUT AND MOUNTING SURFACE 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 Clean all parts in a cleaning solvent Examine for wear or damage and replace as needed Use care when
131. on of a semi locked differential This system acts like a locked differential until the torque at the axle exceeds 50 70 ft Ibs 68 95 2 Nm Atthis 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 Liftthe 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 Ibs 68 95 2 Nm 4 Ifthe 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 70 ft Ibs 95 2 Nm BELLEVILLE WASHER ORIENTATION 103 CHAPTER 19 DRIVES This chapter relates to service of all Right Angle and T drives TUTTA 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 Terug Use approved safety procedures a with eq
132. or Y SEALED BEARING i gt LUBRICATION Oil Bath 32 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 faq It is recommended that you take 7 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 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 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 DISASSEMBLY 1 Remove piping and hydrostatic unit as necessary to allow repair 2 Although the u
133. or when 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 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 u We caution you against the use 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 GENERAL 1 The 1200 series transaxle has three forward speeds and one reverse 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 1200 Housing Bushing and Seal Assy On the 1200 series replace the seals after complete reassembly 72 DISASSEMBLY 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 wei
134. otentially 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 2 04 0 1 6 L ubrication Chart eec Adr e E eee ELS ees M cce SU Cen Pies iden 7 Torque Values Chart ce e HERRERA NER REED COE XE ra ER Re pa TE REX 8 IAG LITIGATION RR RETE 9 10 12 CHAPTER 2 300 Series Lransaxles entente eu 13 CHAPTER 3 e80 S ries Transaxles x tr uuu 14 18 601 Slow Speed 2 e n nennen nennen nennen 19 CHAPTER 4 700 Series In Line Shift 0 enne 21 25 Series Transmissions 000000 hn nne r reser resins 26 29 CHAPTER 5 800 801 Series Transaxl68 5 ee tte 30 36 820 Series Transaxles nieto hber e pee stesse cmt utes deo 37 41 CHAPTER 6 900 Series Transaxles ore i eoe 42
135. over over shift rod and position onto case Torque cover screws 180 216 inch pounds 20 4 24 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 INDEX SET SCREW SHIFT ROD NEUTRAL START SWITCH APPLY LUBRIPLATE 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 1 0 of the splined brake disc The brake pads and brake disc must be free of grease and oil Install 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 yu Follow recommended guidelines 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 820 SERIES TRANSMISSION gt DEDENT BALL SPRING and SET SCREW 9 Same as on Page 7 800 Saries aem QA P Wa 4 SHIFTER and G uw bus SHAFT SX NEUTRAL a COLLAR T Cog P SHIFTING WASHERS e Og Kr OS INPUT SHAFT 06 0000 0 ROUNDED SIDE TOWARDS KEYS x THRUST WASHER 0 RING 0 SHIFTING WASHERS es T
136. ports 85 OUTPUT PINION GEAR AND THRUST WASHERS INPUT SHAFT GEAR AND THRUST WASHERS OUTPUT SHAFT S BRAKE SHAFT BRAKE SHAFT 4 GEAR SHAFT AND THRUST WASHERS 9 Remove the input shaft and gear assembly Note that thrust washers are on both ends of the shaft 10 Remove the output pinion and the gear splined to it Note the position of thrust washers on each end of the pinion 11 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 2 Clean all parts and examine for wear or damage Referto 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 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 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 and brake shafts Install the brake shaft into the gear in the cover Install the inp
137. press that you are using 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 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 REASSEMBLY 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 Install the differential and output shaft simultaneously Position the 3 4 19 1 mm I D gear spacer and thrust washer on the shaft 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 1 0 thrust washer 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 Ibs 13 6 mm Install a new brakeshaft oil seal and axle using seal pro
138. r broken Replace spring Attaching screws for shift lever and housing Torque screws to 10 ft Ibs 13 6 Nm assembly not properly torqued Shifter Brake shaft improperly assembled Reassemble properly per exploded view Keys weak or worn shift gears damaged Replace keys Shift gears Shift lever bent and hitting unit frame Replace shift lever Shift rod grooves worn Replace shift rods Shift rod of improper length or grooving installed Check rod length Replace with correct part Constant mesh gears improperly installed on Reposition gears 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 Bearings not pressed in deep enough Use the proper bearing tool to seat the bearing UNIT DOES NOT DRIVE Differential bevel gears broken Replace Three gear cluster countershaft key sheared in Replace Model 600 Stripped teeth on gears Replace Keys sheared in drive pulleys Replace Broken input gear Replace Shift keys broken Replace keys check keyways and shift gears Reverse chain broken reverse only unless chain Repla
139. r input cage bolts and remove the input cage the assembly will follow 4 Todisassemble 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 5 Remove bearing from gear by using a bearing splitter and puller 6 Remove the shaft out of the cage Remove roller bearing with outside puller toward threaded side Then remove the snap ring When roller bearings and races are removed with a bearing puller discard and do not reuse SNAP RINGS 7 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 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 110 Mtt D i 10 Remove the snap ring 11 Onthe other end use the same puller and remove both the keyed gear and bearing at the same time 12 Remove the snap ring SOFT PLUG 2 13 To remove the 1 3 4 44 5 mm soft plug simply tap it out of the case Discard the old plug 14 To remove races simply tap the race out of the cap and pry the crush ring out
140. r old replace them 10 Install the shifter assembly and bearing strap pack the transaxle with the remaining Bentonite grease 30 ounces total 887 ml Apply grease to the top of the shifter fan 11 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 510334 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 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 1 0 of the splined brake disc The brake pads and brake disc must be free of grease and oil Install 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 Follow recommended guidelines equipment manufacturer s mando for correct brake adjustment Failure
141. ru 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 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 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 THRUST WASHER A flat polished surface separating metals of different hardness It also acts as a spacer between shafts and the case and cover 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 GENERAL SERVICING PROCEDURES The following service procedures should be understood and practiced whenever service is needed on a Tecumseh transmission or drive product TWEEN hel lt 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 A WARNING Use approved
142. s 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 ene model number such as 603 603A 609 etc include 1 Shift lever shape 2 Axle lengths 3 Axle machining for wheel hub attachment 4 Axle housing variations 5 Size of the brake shaft 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 800 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 820 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 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 910 Series The 910 series transaxle offers a forward and reverse unit The speed changes with the use of a variable drive pulley arrangement 915 940 Series This unit has 3 to 5 speeds forward and 1 reverse Reverse is ge
143. se 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 OUTPUT SHAFT SHIFTER BRAKE SHAFT DIFFERENTIAL REMOVED 47 7 Remove the output shaft assembly and the shifter brake shaft assembly SHIFTER BRAKE 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 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 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 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT BEARINGS 135 3 43mm 00002525150 3 82mm THRUST WASHER BEVEL GEAR RETAINING RING REASSEMBLY 1 Apply E P grease between the bearings in the cover and install the input shaft bevel gear and snap ring 2 Grease both keyways and slide keys and collar on shifter brake shaft 48 3 The large beveled shifting gears can be placed onto the shifter brake shaf
144. sembly OIL FILL DRAIN HOLE 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 14 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 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 CHECKING OIL LEVEL PROCEDURE 1 Place the tractor on a level surface 2 Depress the clutch brake pedal engage parking brake and place the deck in lowest cutting position 3 Locate the rubber fill plug next to the shift rod as it enters the transaxle cover 4 Work aneedle 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 DIPSTICK NO 35942 1 2 12 7 mm CONTACT IS FULL 5 Insert the dipstick gauge ata 45 angle Part Number 35942 Check for approximately 1 2 inch 12 7 mm of oil when fully inserted This is 16 ounces 473 ml of EP90 gear oil If oilis needed we recommend using a 16 ounce 473 ml goose neck mechan
145. sembly The four cap screw heads should face away from the output gear or downward BEVEL EDGE OF TOOTH TOWARD LARGE GEAR 3 Install the three gear cluster with the smallest gear facing up NOTE 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 INPUT SHAFT AND GEAR 4 Position the reverse idler shaft in the unit then install the gear and spacer 73 SQUEEZE TOP OF SHIFT 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 p 0 THRUST WASHER 6 Install the output shaft gear spacer and thrust washer 7 Position a new gasket on the cover mounting surface then install the cover 8 Align the cover with the dowel pin and secure with the socket head cap screw Torque to 10 ft Ibs 13 6 Nm 9 Install the axle seals using a sleeve and driver 10 Install the axle supports Be sure the mounting pad position is correct before tightening down the cap screws to 13 ft Ibs 17 7 Nm 11 Install a new gasket and shift lever housing Torque screws to 10 ft Ibs 13 5 Nm Be sure the shift lever is in the proper position to allow shift
146. serious injury NOTE Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty GENERAL 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 IDENTIFICATION This unit contains an aluminum tag showing the model number 56 DISASSEMBLY OF TRANSAXLE Clean outside surface of transaxle Position shift lever in neutral as indicated by the shift pattern The unit may have the OEM option of a neutral start switch remove the switch 2 Remove the Allen head setscrew spring and detent ball Remove the cap screws that fasten the cover to the case 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 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 Car
147. shift collar MUST face the key tips Use work gloves as the keyways on the shifterlbrake shaft are extremely sharp CHAIN SPROCKET SHIFT SPUR GEARS 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 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 BEVEL SPUR GEAR COUNTERSHAFT SPUR GEARS 5 Install the chain over the two shafts making sure that the collars of both sprockets face inward toward the tips of the keys 6 Install the appropriate protection washers on sprocket ends and bronze oil light bushings HUB MUST FACE BEVEL SPUR GEAR REMOVE BEARING COUNTERSHAFT THICKEST THRUST WASHER SHOULDER COLLAR WASHER 7 Install shifter assembly shaft pins and fan 12 oz 355 ml of Bentonit
148. sitioning 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 transaxl
149. speeds It is powered by a Sundstrand hydrostatic drive connected to an engine with up to a 20 Horsepower rating The 2600 series are shipped 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 DISASSEMBLY 1 Remove the hydrostatic pump as necessary to allow repair NOTE An oil supply is blocked in the hydrostatic pump when not running so upon reassembly hydrostatic charging is not necessary 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 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 SUPPORT AND UNIT 5 Toremove 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 6 Position the unit with the cover side up Then remove the dowels and screws Lift the cover off and discard
150. stone or crocus cloth before installation Failure to do so could result in equipment damage death or serious injury cw We caution you against the use 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 GENERAL The 2300 series transaxle is a four speed forward with one speed reverse transaxle BRAKE SHAFT SHIFT LEVER SHIFT LEVER HOUSING INPUT SHAFT HOUSING I D TAG MOUNTING PADS 78 INTERNAL QUAD RING SEAL USED AT THIS POINT ROLL OR DOWEL PIN screws TORQUE TO 10 FT LBS 13 6 Nm SHIFTING FORKS IN NEUTRAL 1 Position the shifter forks in neutral before disassembly SCRIBE MARK IF NECESSARY 2 Remove both axle housings and use the exposed axle as a ram to separate the seal retainers from the case and cover 3 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 4 Oil seals are of the double lip type so sleeve protectors do not offer much protection when removing them Upo
151. straightness and wear 89 Differential AXLE AND DIFFERENTIAL ASSEMBLY CORE BODY AXLE AXLE DRIVE GEAR LIMITED SLIP DIFFERENTIAL 1 Make sure you have all parts are present 2 Check the snap rings for their condition THRUST WASHER COUNTER RETAINER BORE FOR RING RETAINING RING Other 1 Check thrust washers for wear 2 Check tapered roller bearings for wear and ease of rotation 3 Replace the shifter rod oil seal after assembly of all parts 4 Check thrust bearing for wear Replace any parts necessary 90 ASSEMBLY Install parts reversing the disassembly procedure Be careful of the following SETSCREW SPRING BRAKESHAFT RETAINING RING 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 2 Besure that thrust washers and spacers are between every shaft and the case and cover 3 Threads of the differential bolts must be coated with standard stud Loctite The bolt heads on the differential are up when installed 4 Install anew gasket It may be helpful to dampen the gasket with oil to get it to lie flat 5 Usea seal protector to protect the axle support oil seals during installation 6 Install axle supports correctly Do not rotate the support to a new position when pressed tight against the square O ring seal or the
152. t V NOTCH SQUARE CUT SHIFTER GEARS THRUST WASHER SPUR GEAR SHIFTER BRAKE SHAFT FLANGED BUSHING OUTPUT SQUARE CUT SEAL PINION EACH END OF FLANGED BUSHING 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 SHIFTER BRAKE SHAFT CASE HALE OIL SEAL OIL SEAL COUNTER RETAINER BUSHING DIFFERENTIAL FLANGED SHAFT ASSEMBLY BUSHING 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 For teardown and reassembly of the differential see Chapter 18 on differentials Install the differential in the case 10 Install the shifter assembly and pack 30 oz 887ml 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 SET FAN INDEX SCREW BALL SHAFT IDENTIFICATION TAG NOTE On reassembly use
153. t The bevels on the gears face each other and are separated with a neutral spacer Push shifting keys into the neutral spacer Then place a thrust washer bronze bushing and an ring on the shaft The spur gear washer bushing and O ring are assembled to the other end of the shaft BEVEL GEARS 5 Placethe output gear onto the output pinion Install the thrust washers and bushings OUTPUT GEAR OUTPUT PINION OUTPUT SHAFT ASSEMBLY INPUT SHAFT LOWER BEARING BLOCK FLANGE TO THE LEFT 6 Insert the output shaft assembly into the case 7 Prior to installing the differential into the case apply Bentonite grease to the axle bearing surfaces 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 NOTE With models that have an offset input the differ
154. t 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 49 910 SERIES TRANSAXLE MODEL and SERIAL NUMBERS HERE LUBRICATION 18 oz 532 ml of Bentonite grease brake on either left or right side 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 J 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 Trew When shifting gears verify the 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 2 5 carrying a heavy load Shifting on a i hill may cause premature transmission failure which could result in death or serious injury AR 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 3 We caution you against the use of aftermarket variations of braking adjustinents and service
155. t 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 8 43 3 81 mm below flush 43 REASSEMBLY 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 2 Grease both keyways and slide keys and collar on the shifter brake shaft NOTE 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 O RING 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 THRUST NOT 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
156. t shaft will slide out A removed seal must be replaced by a new seal 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 SNAP RING RETAINER SHIFTER FORKS IN NEUTRAL POSITION BRAKE SHAFT SHIFTING ASSEMBLY 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 SHIFTER STOP SHIFTER BRAKE SHAFT This alignment indicates the shifting assembly is ina 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 9 Transaxle Assembly 1 Install new seal thrust washers and bearing on input shaft Note sequence and install into case using a seal protector 2 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 J THRUST BEARING THRUST WASHERS Make sure the bearing and thrust
157. te 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 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 1 120 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 Belt slippage A belt that is worn stretched or the wrong belt too large or wide can cause belt slippage This condition may s
158. tector Install new axle support oil seals using a seal protector Add 2 3 4 pints 44 oz 1301 ml Oil S A E EP 90 before securing the hydrostatic drive to the 1300 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 1300 SERIES HYDROSTATIC GEAR REDUCTION DIFFERENTIAL MODEL and SERIAL NUMBERS HERE 29 1 BRAKE SHAFT M y aPN ae e T E P pz LUBRICATION 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 3 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 When shifting gears verify the 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 carrying a heavy load Shifting on a hill may cause premature transmission failure which could result in death or serious injury Te Use approved safety procedures with equipment for removal installation of axles keyways and hardened shafts Remove all burrs and sharp edges with a honing
159. the 2300 series is the only unit that can be used with ground engaging applications HYDROSTATIC GEAR REDUCTION AND DIFFERENTIAL UNITS 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 1300 Series This unit is the hydrostatic counterpart of the three speed forward unit 1200 Ithas an aluminum casing and pressed through axle support housings which is characteristic of the 1200 series The hydrostatic pump is made by Eaton Manufacturing and is not serviced by Tecumseh Service Dealers 2400 2500 amp 2600 Series This series of hydrostatically 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 700 Series This unit can be 2 3 4 5 amp 6 speeds forward and 1 reverse The brake system can be mounted on either side of the unit 700 H Series This unit is built with almost all interchangeable parts within its two cases except with an H shift pa
160. 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 forthe input shaft The needle bearing on the inboard side is installed 135 150 3 43 3 82 mm below flush ASSEMBLY 1 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 COLLAR DISC BRAKE SPLINE KEY SHOULDER 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 WASHER SEPARATES GEAR FROM BEARING CUT OUT SIDE OF GEAR MUST SHIFT WASHER 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 TH
161. 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 SHAFT BEVEL IF INPUT END OF GEAR SHAFT OTHER END IS OUTPUT END INPUT SHAFT BEVEL GEAR 3 Remove cap screws and both retainer cap and seal assemblies Separate and discard oil seals and gaskets BEARINGS ARE SLIP FIT ON BOTH INNER AND OUTER RACES 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 HOLD GEAR WITH FINGERS THEN TAP ON END OF SHAFT WITH MALLET TO SEPARATE 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 TO REMOVE GEAR REMOVE SNAP TO REMOVE BEARING REMOVE GEAR AND PRESS BEARING INNER RACE TO ALLOW SHAFT AND BEARING TO DROP OUT OF HOUSING 7 Ifnecessary 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 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 p
162. the shifter fan the brake linkage to disengage when the clutch is engaged The brake and linkages may vary Consult the equipment owner s manual A Follow recommended guidelines 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 11 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 510334 or the Loctite Silicone RTV 598 Tecumseh part number 788093A 59 920 SERIES TRANSAXLES INPUT SHAFT SHIFTER and BRAKESHAFT 0 t00 9 NEUTRAL ROUNDED SIDE SHIFTING WASHERS TOWARDS KEYS e COUNTERSHAFT SHIFTING WASHERS NOTE SOME 820 MODELS WILL RUN IN THE OPPOSITE DIRECTION THEREFORE THE LOCATION OF THE LARGE gt BEVEL GEAR WILL CHANGE AND SO WILL THE PLACE MODEL and SERIAL MENT OF THE REVERSE CHAIN AND SPROCKETS NUMBERS HERE CONSULT THE MECHANIC S HANDBOOK FOR PROPER NOTE These models can be built ASSEMBLY THIS IS GUIDE ONLY with brake on either left or right side LUBRICATION Permanent Lubrication 30 oz 887 ml of Bentonite grease Part No 788067C
163. these assemblies are taken apart lay the parts out in a systematic order This should help to make the reassembly easier g 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 BUSHING CHAMFERED SHIFT WASHERS THRUST WASHER _ NOTE INSIDE RECESS FACES KEYS 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 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 REVERSE FOR B INPUT REVERSE DRIVE BEVEL GEAR FORWARD DRIVE BEVEL GEAR T
164. thout the case cover shim and ring Tighten the four bolts to a torque of 200 in Ibs 22 6 Nm at 50 inch pound 5 65 Nm increments 6 Nowremove the cover and place a new case cover shim with a new ring and torque to 200 in Ibs 22 6 Nm at 50 inch pound 5 65 Nm increments SOFT PLUG 7T 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 O RING BEARING RACE RING A SNAP RING 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 9 Press the large race into the cap 111 WOODRUFF KEY 10 11 12 13 112 SNAP RING Place a small snap ring on the shaft 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 WEE IF REQUIRED Press a large shim and a new large roller bearing onto the gear pressing on the inside bearing race Place the shaft into the proper position in the cage and place the gear with the bearing onto the shaft ROTATE CAGE WHILE TIGHTENING NUT 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 be
165. 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 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 which places the sprocket collars away from the shifting gears and spur gears The reverse chain and sprocket is also turned 180 The spacer is then placed in the previous location of the large bevel gear next to the reverse sprocket 930 SERIES TRANSAXLES TOWARDS KEYS SHIFTING WASHERS SHIFTING WASHERS NOTE SOME 830 MODELS WILL RUN IN THE OPPOSITE DIRECTION THEREFORE THE LOCATION OF THE LARGE LUBRICATION Permanent Lubrication 30 oz 887 ml of Bentonite grease NOTE These models can be built Part No 788067C BEVEL GEAR WILL CHANGE AND 50 WILL THE PLACE MENT OF THE REVERSE CHAIN AND SPROCKETS CONSULT THE MECHANIC S HANDBOOK FOR PROPER MODEL and SERIAL 5 298 NUMBERS HERE ASSEMBLY THIS IS A GUIDE ONLY with brake on either left or right side The above illustration is supplied as a general assembly guide your model may be different based on manufacturers requirements 65 CHAPTER 11
166. ttern This unit has 3 or 4 speeds forward and 1 reverse DIFFERENTIALS 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 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 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 ofthe shaft the output shaft will rotate in the opposite direction 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
167. ty recommended This is dictated by the design of the vehicle and position of the transmission unit installed Model Model Model No Quantity No Quantity No Quantity 300 Sealed 700 12 2 355 ml Grease All Models 600 24 2 710 ml Oil 700H 12 2 355 ml Grease Except 4 0z 118 ml Grease 800 30 0z 887 ml Grease 2800 T 1408 P91 801 36 0z 1065 ml Grease 1409 P91 820 36 0z 1065 ml Grease 1410 P91 900 26 7 769 ml Grease 3002 3 0z 89 Grease 910 18 2 532 ml Grease 3003 915 940 10 0z 296 ml Grease 3028 920 30 0z 887 ml Grease 3029 930 30 0z 887 ml Grease 3035 1200 480z 1420 ml Oil tt 1000 Series 6 oz 180 ml 1305 SAE E P 80W90 Oil 1309 32 0z 946 ml Oil 1100 16 2 473 ml 1313 1301 DIFFERENTIALS 1302 All Models 3 2 89 ml Grease 1303 1304 TWO SPEED AXLE 1306 All Models 2 0z 59 ml Grease 1307 1308 THREE SPEED AXLE 1310 All Models 2 0z 59 ml Grease 1311 1312 1314 1315 44 2 1301 ml Oil 1316 1317 1318 1320 NOTICE 1321 Grease Bentonite Grease 1322 Part Number 788067C 1325 1329 Part Number 730229B 1319 T Refer to O E M Technician s Manual for 1323 24 2 710 ml Oil type of lubricant and capacity system 1326 1327 TT To be filled through shift lever opening MST 16 0z 473 ml Oil 2300 1640241892 ml Oil 2400 32 7 946 ml Oil 2500 t 2600 1 M
168. uipment 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 1 Prior to removing the assemblies examine the following items that may have failed causing the right angle drives to appear inoperative 2 Drive belts Inspect for breaks tension oil or grease saturation and inoperative tightening devices 3 Pulleys Tighten retaining screws Examine for sheared keys 4 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 5 Loose blade retaining nuts Check torque and tighten if required 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 DISASSEMBLY 1 Scribe marks on the covers and shafts to ease in reassembly 2 Remove the cover gasket and the lubricant from the drive 104 DRIVE BEVEL GEAR FINNED COVER DRIVEN BEVEL GEAR OUTPUT SHAFT IN LOWER POSITION 3 Output shafts achieve a different rotati
169. ut and output shafts with gear and position spacers on the brake shaft Install thrust washers on all shafts THRUST WASHER INPUT SEAL BRAKE THRUST WASHER OUTPUT NOTE POSITION OF CAP SCREW HEADS cepta CASE COVER seges i 0 RING B SPACER INPUT SHAFT Install the differential unit with cap screw facing down 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 Ibs 13 6 Nm 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 Ibs 13 7 Nm Using the proper seal protector and driver replace the input and brake shaft seals Rotate shafts to check for binding or noise 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 THRUST WASHER SPLINED COUPLING SEAL THRUST WASHER NOTE POSITION OF AXLE SUPPORT SEALED BALL BEARING I _ NOTE EQUAL LENGTH AXLE EXTENSION FROM EACH SUPPORT 2400 SERIES HYDRO POWERED TRANSAXLES 9 SEALED BEARING ge MODEL and SERIAL NUMBERS HERE NS INPUT SHAFT 7 SES UNE 9 Pc 7 s9 m nos ee 7 ge p
170. ver over the shift rod and position onto BEVEL GEAR CENTER SHAFT the case Install the cover cap screws and torque 90 100 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 PINION 5 Check for binding by turning the input shaft GEARS LL GEAR 9 Placethe 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 13 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 1 0 of the splined brake disc The brake pads and brake disc must be free 10 Install the shifter assembly and bearing strap pack of grease and oil Install brake assembly the transaxle with the remaining Bentonite grease 4 30 ounces 887 ml total Apply grease to the Install the transmission on the equipment Adjust top of
171. verse 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 SPUR GEAR WASHER 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 WASHER m me WASHER is BUSHING BUSHING OUTPUT PINION OUTPUT GEAR 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 See Assembly Variations on page 64 63 CENTER SHAFT BEVEL GEAR BEVEL PINION GEARS BEVEL GEAR 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 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 o
172. wards the shift keys Continue this procedure until all the gears on both shafts have been added NOTE It is not only important that gears match diameter wise but must match up according to thickness As all the gears are placed back into the assembly pack each with bentonite grease BEARING _ ASSEMBLY SLEEVE NEEDLE BEARING O RING ASSEMBLY SPACER WASHER THRUST BEARING 6 In the model pictured above a thrust washer thrust bearing thrust washer and sleeved needle bearing with an 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 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 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 n
173. washers remain in place while assembling the idler gear shifter and brake shaft SHIFTER SA af s SHIFTER RODS THREE GEAR CLUSTER 3 Insert the washer and then the three gear cluster assembly Make sure the bevels on the two shifting gears are facing down 4 Insert the shifter assembly Check that the shifter rods are seated properly 5 Install the reverse idler Make sure the beveled edge is up Place the spacer on top of the gear CENTER PLATE ASSEMBLY 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 SEAL PROTECTOR GT E A 2 CENTER PLATE ASSY 7 Install the cover assembly and torque the cap screws to 7 9 ft Ibs 84 108 in Ibs 9 5 12 2 Nm 8 If the unit needs bearings or bushings installed consult Chapter 22 for proper procedures 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 10 Inspection Note For a neutral position shift notches in forks and notch in stop must be aligned and centrally located APPLY LUBRIPLATE 11 The brake lever type is determined by the original equipment manufacturer s selection of this opti
174. wing procedures are accurate and the preferred method for a quick check of the unit On an 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 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 Gaskets were left out on reassembly or installed incorrectly 2 Oilseal retainers differential thrust washers shifter Stop or oil seal retainers were installed improperly 3 The shifter assembly or spacers were installed incorrectly 4 Foreign matter could be blocking the gear teeth that are in mesh 5 Theinput 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 LUBRICATION CHART Check the Transmissions unit model and specification number before filling with lubricant There may be a difference in the quanti
175. 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 670293 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 106 DISASSEMBLY 1 Scribe marks on the covers and shafts to aid in reassembly BEARING AT INNER EDGE OF MACHINED SURFACE DRIVING BEVEL GEAR SNAP RING 3 Ifthe 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 SNAERING OUTPUT SHAFT 4 Remove four screws and the cover seal assembly 5 Remove the seal at the output shaft 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 BEVEL GEAR OUTPUT SHAFT 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

TECUMSEH & PEERLESS - Small Engine Suppliers

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TECUMSEH &amp; PEERLESS - Small Engine Suppliers

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TECUMSEH & PEERLESS - Small Engine Suppliers