K92 Service Manual ()
Contents
1. Charge Pressure q 2WD amp 4WD Test Port 8 cc rev Reading 1950 10360 kPa x I 0 27 oz rev 283 1502 psi i s ee 1958 48 kPa f l 284 7 psi a l A I I L Check Tow Val s 1 ec ow Valve I 4 9 T 3 Reverse Charge Pressure V Control Valve A F N E 8 8 mm 8 8 I I P x Hp cy Anti Cavitation i Charge Pump Flow Z Check Valve x l 8 cc rev 17 22 7 I m 4 5 6 gpm I Anti Cavitation k 12 Li Screen i 10y o H d li ut I er l TETE 1 E Suction Line E HST High Pressure Line PTO Pressure Line BEE HST Low Pressure Line Milli Charge Pressure Line 45 Troubleshooting Guides Note f your specific problem and or solution is not listed below consult a qualified Tuff Torg Disstibator Hydrostatic Transmission Problems Machine will not move on its own power Free wheeling linkage set for push or partially set Control pedal linkage bent binding or disconnected Directional control valves leaking or stuck down Brakes set or not releasing Anti cavitation valves leaking or stuck open Charge pump scored or worn Pump or motor valve plates scored or worn Charge pressure relief valve leaking Seat valve or spring damaged Drive shaft not turning pump input shaft or charge pump key sheared 999999944 Machine will not move Wheels locked up Brakes set or not releasing Will not move in one direction Free wheeling linkage set for push or part2. TUFF TORA SERVICE MANUAL 92 Table of Contents 4WD Output Disassembly and Assembly eee eee ee 24 Brakes Removal and Installation 2 200202002200000000 00000 nnen anne nnnn nennen 43 Center Valve Block Disassembly and Assembly eee eee eee 33 Charge Pump Disassembly and Assembly sse eee ee eee 2 Charge Pump Removal and installation sees 2 Control Arm and Damper Removal and Installation e eee ee eee 1 Differential 2WD Disassembly and Assembly eee eee ee 20 Differential 4WD Disassembly and Assembly sese eee eee 21 Differential Lock Shaft Disassembly and Assembly eee eee 19 General SpEcCINCaANONS are ee en nee damned nace eens IV Hydrostatic Flow Diagram Check Points cccceccccececceeeeceseeseeseceesesensesanees 44 Hydrostatic Pump MVOC HO agen nee een 35 Hydrostatic Transmission 2WD and WVD esse eee 28 Hydrostatic Transmission installation eee ee ee eee 35 Hydrostatic Transmission Motor Disassembly and Assembly 2WD 29 Hydrostatic Transmission Motor Disassembly and Assembly AWD 31 Hydrostatic Transmission Motor Installation u2 200220002400220 Rennen 34 Inspection of Transaxle Case eee eee 39 K92 Transmission Component Location sese ee eee vi Ordering Replacement Parts Online u ji PTO Brake Removal and Installation esse eee eee 6 PTO Clutch Disassembly Inspection and Assembly eee ee eee ee 22 PTO D
3. 1 Clean mating surfaces of cover AD and gear case C Be sure threaded holes are clean Fig 37 2 If removed install gear sets in the reverse order of their disassembly Fig 37 3 Apply a bead of silicon sealant to any mating surfaces to be assembled IMPORTANT Avoid damage Carefully lower cover assem bly onto case making sure bearings fit into bores and gears mesh properly Be sure cover is installed within 3 mm 178 in of case before tightening all cap screws to 25 Nem 18 Ib ft Major damage can occur to cover and or case if not properly aligned before tightening cap screws 4 Install PTO assembly on the two alignment bushings and tighten tenF and three M8 x 50 E cap screws to specification below 5 Install transaxle drain plug Refill transaxle with approxi mately 9 0L 9 5 qt using ATF Type F to crosshatched area of dipstick Specifications v MB BONS su Jansen 24 Nem 18 Ib ft e M12 Bolts ccc cece ee eee 54 Nem 40 Ib ft 18 Tuff Torq K92 Hydrostatic Transaxle Differential Lock Shaft Disassembly and Assembly Fig 38 Differential Lock Shaft Disassembly A Snap Ring 2 used B Spring C Sleeve 2 used D Fork E Shaft F Spring G Washer 1 Remove roll pin H washer G and spring F Fig 38 2 Remove snap rings A sleeves C spring B shaft E and fork D Fig 38 3 Inspect shaft E and fork for wear or damage Replace
4. F Snap Ring 3 Repeat for other side if necessary Installation is done in the reverse order of removal G Axle Housing H Bushing 2 used Cap Screw 6 used J Washer 41 Rear Axle Assembly Disassembly and Assembly 6 Fig 76 Rear Axle Assembly Fig 75 Rear Axle Disassembly l l 9 Install axle shaft assembly into axle housing using a Remove large snap ring B from groove of axle housing press Press shaft only until a rapid increase in pressure G Fig 74 is noticed Use a press to remove axle shaft A from axle housing G Fig 75 Remove remaining snap ring to remove axle shaft com ponents Inspect axle shaft and housing for wear or damage Replace parts as necessary Inspect bearing for smooth rotation Replace if neces sary NOTE Ball bearing is not pressed into housing When placed in axle housing it may be loose A clearance up to 0 38 mm 0 015 in is normal Install bearing seal and snap ring into axle housing Put Fig 77 Rear Axle Cut away spring side of seal into housing first Apply petroleum jelly to lips of seal and inner diameter of sleeve 10 Install washer E and snap ring C on axle shaft Fig 77 11 Use a piece of pipe D with a minimum inside diameter r l L dsl as of 31 mm 1 3 16 in maximum outer diameter of 43 HSS a a Ne mm 1 11 16 in and approximately 330 mm 13 in a piece of pipe with a minimum inside diameter of 31 long to install sna
5. the pump must be removed 1 Disassemble all parts of charge pump D Fig 3 2 Inspect O rings C K L M and Q for cuts or damage Replace as necessary Fig 3 NOTE Pump gerotor N and P seal X body D and pressure reducing valve S parts must be replaced as a set 3 Inspect gerotor charge pump parts N P Replace parts if worn chipped scored or damaged 4 Remove plug U to remove pressure reducing valve parts V S and T Fig 3 5 Inspect parts for scoring wear or damage Directional Control Valves Removal and Installation Fig 4 Control Valves 1 Remove directional control valves A Fig 4 NOTE Installation is done in the reverse order of removal e Tighten directional control valves to 35 Nem 26 Ib ft Disassembly Inspection and Assembly RC k ae Fig 5 Control Valve Disassembly A Reverse Control Valve with orifice B Orifice C Forward Control Valve D O ring E Backup Ring F O ring 1 Disassemble parts from directional control valves 2 Inspect O rings and backup rings for damage 3 Plunger pin must move freely 4 Internal valve must move freely when valve is shaken 5 Make sure orifice and all passages are free of any obstruction 6 Assemble parts IMPORTANT Avoid damage The reverse control valve must be installed in the left port The control valve can be identified by a small orifice drilled into a land betwe
6. E Cover must be replaced as a set F Snap Ring 3 Inspect transaxle cover components G Washer 4 Check bushing bearing and swash plate contact sur faces for wear or damage Replace as necessary H Cap Screw 5 Inspect O rings on swash plate and eccentric adjust iaia fulcrum for cuts or damage E ii 6 Install soring so legs are crossed and each leg of spring K Nut fits into a groove of the fulcrum cap screw L Washer 7 If swash plate bearing was removed install new bearing pi d until end of bearing is even with the inside surface of NEPON SRU the cover SHS 8 Put petroleum jelly on all O rings Install swash plate O Eccentric Adjust Fulcrum assembly and remaining components P Swash Plate NOTE Use medium strength thread lock and sealer 38 Tuff Torq K92 Hydrostatic Transaxle Inspection of Transaxle Case Fig 67 Front PTO Shaft Port Fig 69 PTO Brake Pin Port Swash Plate Bearing and Vent Cap 1 Remove front PTO shaft seal B Fig 67 7 Inspect PTO brake pin sleeve E for scoring or damage 2 Inspect needle bearing A for wear or damage Remove Replace if necessary if necessary Install new needle bearing from inside case 8 Push sleeve out from inside of case with bearing identification marks toward the inside of rae l 9 Install new sleeve into case until flange of sleeve is tight the case Push bearing tight against shoulder in bore I J against case 3 Install new seal wi
7. H E HEH iii Having your Model and Model Series click on the serial number to enter the Online Ordering page for you Transaxle Ref 6 Navigate through the exploded parts illustration until the desired part has been identified Take note of the parts figure number Locate the part number in the parts listing You can add the part to your shopping cart and return to the exploded illustration or click on the item to go to the Product Explorer page for additional detail about the part Ref Page 7 Thank you for visiting and ordering online with Tuff Torq Recommended Tools and Equipment Serial Number Location 1 Solenoid Valve Socket Transmission Gear Spacer Bushing Bearing and Seal Driver Set Press Snap Ring Pliers Knife Edge Puller Hoist Silicon Sealant O o a o m Mn Cure primer 10 Thread Lock and Sealer Medium Strength General Specifications Transaxle 5 cle on Olli RE BO ATF Type F Capacity With Filter 2WD ee RER en 7 5 L 7 9 qt Capacity With Filter AND ae u era een 7 8 L 8 2 qt Capacity With Filter 4WD w rear PTO arena ea 9 0 L 9 5 qt Charge Pump DEOR CIO ee A ee ee eee ree 8 cc 0 49 cu in rev Charge Pressure Control Valve MINIMUM seen 1950 kPa 283 psi Charge Pressure Relief Valve Implement Pressure minImum sss 9360 kPa 135 psi TSS PUB FIOW ee ee ea ee ee 22 7 L m 6 0 gpm NINO FIO Waran ee een er eeren 17 L m 4 5 gpm PTO PITO 3 a Ui a8 COntrol VAVE
8. W Collar X Shaft Reduction 4WD Y Gear 4WD Z Washer AA Gear AB Bearing AC Gear AD Ring AE 4WD Gear Box Gasket AF 4WD Gear Box Cover Gasket Fig 52 4WD Output Disassembly AG Bolt AH Bolt Al Washer AJ Guide Pin AK Bolt AL Bolt AM Ring AN Ring AO Bearing AP Keeper Plate AQ Spring AR Detent Ball 27 Hydrostatic Transmission 2WD and 4WD Hydrostatic Transmission Removal Hydrostatic Transmission Motor Removal 1 Remove charge pump See Charge Pump Removal and Installation on page 2 IMPORTANT Avoid damage Do not drop or damage pump valve plate when removing center valve block assembly Do not nick or scratch lapped or machined surfaces of the valve plates or cylinder block components The slightest damage can cause poor performance Fig 54 2WD Shown 4WD similar 2WD Shown 1 Remove retaining ring B bevel input pinion C and ball bearing A 2 Inspect bearing for smooth rotation NOTE Bevel input pinion and bevel input gear must be re placed as a set 3 Check pinion for wear or damage Fig 53 2WD Shown 4WD similar 4 Replace retaining ring if ring is distorted during remov 2 Remove cap screws A leaving in place 2 cap screws al D Carefully remove center valve block B and motor assembly from transaxle 3 Replace gasket C if torn or damaged 28 Tuff Torq K92 Hydrostatic Transaxle Hydrostati
9. a suitable solvent Dry with com pressed air IMPORTANT Avoid damage DO NOT spin bearing using compressed air Damage to bearing balls cage and races could result 11 Inspect bearings for discolored burned balls and or races Check balls and races for spalling or cracking Roll bearing by hand to check for rough turning or excessive looseness or play between balls and races Replace bear ings as required Fig 45 4WD Cover Removal NOTE Snap ring AD on motor shaft does not need to be removed for the 4WD gear case removal Unless replacement is necessary Fig 52 Fig 47 4WD Cover Removal 24 Tuff Torq K92 Hydrostatic Transaxle 12 Remove bolt F and keeper plate AP from the 4WD 16 Remove the bearing E from the 4WD output shaft N oe 17 Carefully remove front shift collar Q from 4WD output 13 Use drift to drive out spring pin L and roll pin M shaft As separation occurs the detent balls AR and securing 4WD shift arm C to 4WD shift shaft G then spring AQ will become visible Fig 50 remove 4WD shift arm from the 4WD shift shaft Replace if damaged or worn CAUTION Detent Balls are under pressure from spring while assembled Care should be taken during disassembly to in NOTE Replace O ring K see fig 52 on 4WD shift shaft sure that they do not fly out possibly causing damage and or when reinstalling injury Safety glasses should be worn at all times while work ing on th
10. are being compressed Tuff Torq K92 Hydrostatic Transaxle Center Valve Block Disassembly and Assembly Fig 57 Center Valve Block Disassembly A Holder K Top Plug B Spring L O ring C Ball M O ring D Push Pin N Washer E O ring O Shim 0 5 F Seal P Shim 0 2 G O ring Q Spring H Back up Ring R Charge Pressure Relief Valve Plunger O ring S Reverse Check Valve J Forward Check Valve T Seat 33 Center Valve Block Disassembly and Assembly continued U Center Valve Block V Needle Bearing 2 used W Locating Pin 2 used X Pump Valve Plate Y Anti Cavitation Valve Body Z Backup Ring AA O ring AB Ball AC Ball Holder AD Spring AE Retainer AF Motor Valve Plate NOTE Remove motor assembly if necessary to inspect nee dle bearing See Hydrostatic Transmission Motor Removal on page 28 1 Remove and inspect directional check valves IMPORTANT Avoid damage The reverse check valve must be installed in the left port The check valve can be identified by a small orifice drilled into a land between the two sets of valve passageways 2 Replace locator pins if missing or damaged 3 Inspect needle bearings for wear or damage If bearings are replaced install new bearings with the stamped end away from center valve block 4 Push bearings into bore until end of bearing is approxi mately 3 mm 7 64 in above the surface of the valve block 5 Ins
11. ee ee ee ee ee 1500 2000 kPa 218 290 psi MUST ateb d een ee Eee 1 5 1 2 L m 0 40 0 48 gpm Repair Specifications lt T e Cap Screw ONS ee ee en ls tected ees 73 Nem 54 lb ft PIO SolenoidArmature pe co Weer nee ea ee en nee ee He 22 Nem 195 Ib in PTO Solenoid Nut TOR Serena nee ee ERSTE 4 9 Nem 43 Ib in Iv Tuff Torq K92 Hydrostatic Transaxle General Specifications continued Transaxle Cover Cap Screws Used Transaxle Case TOS neueren rear een 25 Nem 221 Ib in New Iransaxie Case TOrgUe ee ee ea 30 Nem 22 Ib ft PTO Output Shaft Retaining Cap Screws TOrque ee nee 27 Nem 20 Ib ft PIO SARE nant Cap STEW WONG Ci seg csc cess een as een 25 Nem 221 Ib in PTO Bal Switches VS ee een 34 Nem 25 lb ft PTO Clutch Pack Wear Clearance Between Plate and Bottom of Gear Hub GrOOVe sss 2 7 mm 0 106 in maximum Charge Pump Cap Screws Snort Cap Screws ee U ee ers tee ae ee 25 Nem 221 Ib in Long lope 01 0 ree 39 Nem 29 Ib ft Hydrostatic Motor Seal Cap Depth below Housing nn een ee 4 mm 5 32 in Beie ap CTW Jorge ee en EN 39 Nem 29 Ib ft Hydrostatic Motor Seal Cap Depth below Housing nannte 4 mm 5 32 in Hydrostatic Center Valve Block Directional Control Valves TOrque aa er DR RN anes 35 Nem 26 lb ft Bottom SUCTION FUG TOGUE sesa EE EIER EIER 50 Nem 37 Ib ft Charge Pressure Relief Valve Plug Torque 25 Nem 221 Ib in Mounting Cap Screws TOrque ernennen nee 39 Nem 29 lb ft Axle H using Cap
12. gt for 4WD w rear PTO CAUTION Avoid njury Allow transaxle to cool before drain ing fluid Hot fluid can cause serious burns Fig 12 Relief Valve Plug 1 Remove relief valve plug Fig 12 2 Install relief valve plug A and tighten to 25 Nem 19 lbft Fig 4 Transaxle Rear PTO Cover Tuff Torq K92 Hydrostatic Transaxle 1 Remove plug B to drain oil from transaxle Fig 14 NOTE If rear PTO is installed remove necessary rear PTO components before rear transaxle cover removal See Rear PTO Removal and Installation on page 12 2 Remove optional rear PTO A if installed See Rear PTO Removal and Installation on page 12 Fig 14 3 Remove rear transaxle cover C Fig 14 4 Remove control arm damper D Fig 14 15 to gain access to 3 cap screws K Fig 15 holding PTO brake cover J Fig 15 to transaxle side cover See Control Arm and Damper Removal and Installation on page 1 Fig 16 PTO Brake Cover Kit NOTE Installation is done in the reverse order of diassembly PTO Brake Disassembly Inspection and Assembly Fig 17 Transaxle Case Side Cover Fig 7 PTO Brake Disassembly CAUTION Avoid Injury PTO brake cover is spring loaded Remove cap screws evenly to release spring force A Collar Brake Pin F Stopper B O ring G Spring Inner C Pin PTO Brake H Spring Middle D Snap Ring 2 used Spring Outer E Pi
13. rear PTO Removing 1 Remove plug B to drain oil from transaxle Fig 18 Tuff Torq K92 Hydrostatic Transaxle NOTE Remove necessary rear PTO components before rear transaxle cover removal See Rear PTO Removal and Instal lation on page 14 2 Remove optional rear PTO A if installed See Rear PTO Removal and Installation on page 14 Fig 18 3 Remove rear transaxle cover C Fig 18 Fig 8 Transaxle Cover Remove PTO clutch assembly A Fig 19 Remove PTO idler gear assembly N Fig 19 Remove PTO gear K Fig 19 R ae Se Left axle must be removed to remove PTO output shaft assembly L See Rear Axle Assembly Removal and Installation on page 41 PTO Drive Train Mid PTO Removal and Installation continued 8 Inspect ball bearings and needle bearing for smooth rotation NOTE Idler gear N and shaft O must be replaced as a set Fig 19 9 Inspect gears and splines for missing or chipped teeth wear or damage Replace parts if necessary Fig 19 Rear PTO Cover Removed A PTO Clutch Assembly B Snap Ring C Needle Bearing D Washer E Seal F Needle Bearing G Washer H Cap Screw Ball Bearing J Snap Ring K Mid Mount PTO Gear L PTO Output Shaft M Snap Ring N PTO Idler Gear O PTO Idler Shaft P Washer Fig 20 PTO Drive Train Mid PTO Disassembly Installing 1 8 If replaced insta
14. 1 Spring is compressed Apply an external force to com press spring farther before removing snap ring Then slowly remove external force 2 Remove parts from transaxle as necessary NOTE Pump rotating components must be replaced as a set Thin thrust plate must be replaced as a set with the pump swash plate and bushing 3 Check cylinder block for grooves scoring discoloration or pitting NOTE Scoring is fine scratches or grooves cut into the highly machined surface When the scratches can be detected by feel using a lead pencil or fingernail the part must be replaced 4 Check for free movement of pistons in cylinder bores 5 Check pistons for flat areas scoring or discoloration Thrust bearing must rotate freely For inspection of pump valve plate refer to Center Valve Block Disassembly and Assembly on page 33 Transaxle Disassembly 1 Remove control arm damper See Control Arm and Damper Removal and Installation on page 1 2 Remove hydrostatic transmission and pump See Hy drostatic Transmission 2WD and AWD on page 35 3 Remove axle housings See Rear Axle Assembly Re moval and Installation on page 41 and See Rear Axle Assembly Disassembly and Assembly on page 42 4 Remove brakes See Brakes Removal and Installation page 43 36 5 Remove PTO idler shaft assembly C snap ring E PTO gear D or rear drive gear set Fig 62 With Rear PTO O
15. 7 9 qt for 2WD and 7 8L 8 2 gt for 4WD and 9 0L 9 5 gt for 4WD w rear PTO Removing Fig 2 1 PTO Drive Train Mid and Rear PTO Removal NOTE Remove necessary rear PTO components before rear transaxle cover removal See Rear PTO Removal and Instal lation on page 14 Remove rear PTO AD See Rear PTO Removal and Installation on page 14 Remove 9 cap screws AC to remove rear cover AB Fig 21 Remove PTO clutch assembly A Fig 22 IMPORTANT Avoid damage When removing snap ring B be sure not to lose needle bearing C or washers D Remove PTO idler gear assembly U Fig 22 Remove snap ring L spline collar K and remove mid mount and rear mount PTO gear assembly I Fig 22 Left axle must be removed to remove PTO output shaft assembly R Fig 20 Inspect ball bearings and needle bearings for smooth rotation PTO Drive Train Mid and Rear PTO Removal and Installation continued 8 Inspect gears and splines for missing or chipped teeth wear or damage Replace parts if necessary Fig 22 PTO Drive Train Mid and Rear PTO Disassembly A PTO Clutch Assembly K Spline Collar B Snap Ring L Snap Ring C Needle Bearing M Cap Screw 2 used D Washer N Washer E Seal O Needle Bearing F Snap Ring P Washer G Spacer Q PTO Idler Shaft H Ball Bearing R PTO Output Shaft Mid Mount and Rear Mount PTO Gear S Ball Bearing J N
16. Locking Pin washer and cap screw Tighten cap screw C to 73 Nem E Washer 54 lb ft Dampei NOTE Ifremoved use medium strength thread lock G Pivot Stud and sealer on pivot stud G threads H Clevis Pin 7 Install damper with open end of clamp facing down Spring Locking Pin 8 Install remaining washers and spring locking pins 1 Remove spring locking pins D and washers E from both sides of damper F Fig 1 CAUTION ALWAYS WEAR SAFETY GLASSES WHILE PER 2 Slide damper off of pivot stud G and clevis pin H FORMING ANY MAINTENANCE ON TRANSAXLE Inspect and if defective replace damper as an assembly 3 Toremove control arm A remove spring locking pin I and disconnect foot control rod D from control arm NOTE Access to cap screw C is through hole in right frame Charge Pump Removal and Installation Be at Rr NOTE Installation is done in the reverse order of removal e Tighten 2 short cap screws A to 25 Nem 18 lb ft e Tighten long cap screw Y to 39 Nem 29 lb ft NOTE Approximate capacity of hydrostatic power train is 7 5L 7 9 qt for 2WD and 7 8L 8 2 gt for 4WD and 9 0L 9 5 gt for AWD w rear PTO Fig 2 Charge Pump Rotor IMPORTANT Avoid damage Do not drop pump gerotor P or lose key O Damage to machined surfaces will cause poor performance and premature failure Fig 2 1 Remove drain plug to drain oil before starting any disas sembly of the tra
17. N Fig 40 placed as a set Bevel input gear B and bevel input pinion not shown must be replaced as a set 2 Inspect differential components 9 Check bevel input gear B and final pinion shaft C for ge Bean aali aiin aaas worn or damaged condition Replace parts as necessary necessary 10 Install final gear on differential holder and carrier with the deeper offset of gear center away from the holder Tighten eight differential cap screws P to 88 Nem 65 lbft 11 Install differential lock collar Q and left bearing E Push bearing tight against shoulder of differential 6 Check differential holders F and N and differential holder pinion shaft K for wear cracks or damage Fig 40 4 Check differential components for wear or damage If replacement is necessary all parts must be replaced as Set 5 Inspect differential lock collar for wear or loose or sheared off pins 12 Install remaining components 7 Inspect final gear M for worn or damaged teeth NOTE Use medium strength thread lock and sealer NOTE Pinion gears J 2 used washers I 2 used and dif ferential pinion shaft K must be replaced as a set 8 Inspect ball bearings A and D for smooth rotation PTO Clutch Disassembly Inspection and Assembly Fig 41 PTO Clutch Disassembly 22 A Ball Bearing B Snap Ring C Clutch Shaft D Needle Bearing E Washer F O ring G Piston H Spring Washe
18. NT Avoid damage Be sure cover is aligned with transaxle case and installed within 4 mm 1 8 in of case be fore tightening cap screws Major damage can occur to cover and or case if cover is not installed properly before tightening cap screws Rear PTO Gear Case Cap Screw Torque Specifications e Used Transaxle Case 25 Nem 18 Ib ft e New Transaxle Case 30 Nem 22 Ib ft Fig 24 Rear PTO Cover Assembly 8 Install transaxle drain plug Refill transaxle with ap proximately 9 0L 9 5 qt using ATF Type F as required to crosshatched area of dipstick 9 Install any additional items removed prior to PTO 13 Rear PTO Removal and Installation NOTE Approximate capacity of hydrostatic power train is 9 0L 9 5 gt for 4WD w rear PTO Removing CAUTION Avoid Injury Allow transaxle to cool before drain ing fluid Hot fluid can cause serious burns 1 Remove plug AA to drain oil from transaxle Fig 25 Fig 26 PTO Rear Case Cover Disassembly and Assembly 1 Remove cover from PTO gear case C Fig 27 2 Remove cap screw A and plate B and pull shifter shaft E from PTO gear case C Replace O ring on shifter shaft and apply thin coating of clean hydraulic oil before reinstalling Fig 27 Fig 25 Rear PTO Gear Case Cover 2 Remove 14 cap screws AC and PTO gear case cover assembly AD Fig 25 NOTE Remember to install two different sized cap screws i
19. O Remove press bearing U and remove washer Q from idler shaft P Inspect all components for wear or dam age replace as necessary Fig 34 Fig 36 Ball Switches 15 Inspect all parts and replace as necessary Assembly is reverse order of disassembly Fig 34 Rear PTO Pinion Input Gear Disassembly NOTE If rear PTO input gear R see fig 34 replacement is necessary the shift collar F see fig 36 and rear PTO idler gear G see fig 35 must be replaced also The three gears are available as a set Rear PTO gear T see fig 33 and rear PTO idler pinion O see fig 34 must be replaced as a set 16 Rear PTO Assembly Tuff Torq K92 Hydrostatic Transaxle Cap Screw Spring PTO Case A B C D O ring E Shifter Shaft F Spring G Idler Gear H Snap Ring Bearing J Idler Shaft K Bearing L Snap Ring M Bearing N Washer O Idler Pinion Gear 17 Fig 37 Rear PTO Disassembly P Shaft Q Washer R Input Gear S Bearing T Rear PTO Gear U Bearing V Ball W Bearing X Rear PTO Shaft Y Spring Z Snap Rings AD Rear PTO cover BB Fork Kit CC Fork Shaft DD Seal Rear PTO Removal and Installation continued Installing NOTE Installation is done in the reverse order of diassembly Additional information can be found by refering to the Rear PTO Removal and Installation removal section starting on page 14
20. Screws OT 54 Nem 40 lb ft Kna TLSTR W TOGUE ee T E 54 Nem 40 Ib ft Transaxle to Frame Mounting Cap Screws and NULS sss esse sese 71 106 Nem 52 78 Ib ft Differential Cap Screws Torque 88 Nem 65 Ib ft Drive shalt Cap STEWS Ke 6 0 lt 1 ee ee i 40 Nem 30 Ib ft Hydraulic Hine Fittings TOGU G een nee en rare ah 24 Nem 212 Ib in K92 Transmission Component Location Oil Port Fill Tube not Shown Forward Reverse Main Transmission Case PTO Brake Cover Control Valves PTO Pressure Test Port Charge Pump Control Arm Damper 4WD Assembly PTO Electrical Optional Engagement Solenoid Center Block Valve Motor Case Assembly Brake Arm C Sr ne o PTO Pressure Brake Assembly i ee Control Valve L Rear PTO Shaft Optional Differential Lock Arm Differential Lock Shaft Axle Assembly K92 Hydrostatic Transaxle vi Tuff Torq K92 Hydrostatic Transaxle Control Arm and Damper Removal and Installation Before beginning tear down clean work area thoroughly and cover workbench with clean paper This is extremely impor tant as just one grain of sand can cause damage to the Hy drostatic Rotating Group in the Transaxle Fig 1 Control Arm and Damper Disassembly A Control Arm 4 Remove cap screw C and washer B from control B Washer arm Fig 1 C Main Cap Screw 5 Remove control arm A Fig 1 6 Install control arm the same as removal and install D Spring
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22. c Transmission Motor Disassembly and Assembly 2WD Fig 55 Hydrostatic Transmission Motor Disassembly 2WD A Cap Screw 2 pieces S Piston B Seal Cap T Gasket C Snap Ring U Thick Thrust Plate D Snap Ring V Thrust Bearing E Washer W Bushing F Ball Bearing X Thin Thrust Plate G Motor Case IMPORTANT Avoid damage Do not drop or damage mo H Locating Sleeve 2 used tor valve plate when removing motor assembly Do not nick or scratch lapped or machined surfaces of the valve plate or Motor Shaft cylinder block components The slightest damage can cause J Center Valve Block Assembly poor performance K Locating Pin 1 Remove two cap screws A Fig 55 L Motor Valve Plate IMPORTANT Avoid damage Keep pistons S matched with r bore of cylinder block P Do not interchange motor pistons M Snap Ring j i and valve plate L with pump pistons and valve plate Pistons N Washer and cylinder blocks are a matched set O Spring 2 Remove cylinder block assembly P Cylinder Block NOTE Motor rotating components must be replaced as a Q Shim set R Piston Spring 29 Hydrostatic Transmission Motor Disassembly and Assembly 2WD continued 3 Inspect rotating components NOTE Apply silicon sealant to outer edge of new seal cap Install seal cap until cap is approximately 4 mm 5 32 in be NOTE Scoring is fine scratches or grooves cut into the highly low surface of motor case mach
23. collar pin or differential carrier fail ure Troubleshooting Guides Transaxle Engagement Problems continued Differential lock will not engage Differential lock linkage is mis adjusted Differential lock collar pin or differential carrier fail ure Differential lock will not disengage Brakes are applied or mis adjusted Differential lock linkage is mis adjusted Differential is engaged Check adjustment and or repair differential lock Differential lock collar pin or differential carrier fail ure 99 Transaxle Noise Problems Ratcheting noise as machine moves Brakes are applied or mis adjusted Differential lock linkage is mis adjusted Differential is engaged Check adjustment and or repair differential lock Differential lock collar pin or differential carrier fail ure Check axle or differential gear failure Z 09094 Ratcheting noise as machine turns _ Differential lock linkage is mis adjusted Differential is engaged Check adjustment and or repair differential lock Differential lock collar pin or differential carrier fail ure Check axle or differential gear failure 48
24. e ID Pilot Hole 17 0 17 02 mm 0 669 0 670 in 25 Measure shaft bore in 4WD cover If not in specifications replace housing 26 Measure OD of shaft in bearing area If not in specifica tions replace shaft Specifications e Shaft OD o n 16 93 17 mm 0 667 0 669 in e AND Cover Shaft Bore ID 17 17 043 mm 0 669 0 671 in Assembly and Installation Assembly and installation of the 4WD output assembly is car ried out in reverse order of disassembly and removal Replace the gasket AE see fig 52 and gasket AF only if 4WD gear case was removed or use a thin bead of silicone sealant between motor case assembly and 4WD gear case Also between 4WD gear case and 4WD cover Refill transaxle w approximately 7 8L 8 2 qt for 4WD and 9 0L 9 5 qt for 4WD w rear PTO Use ATF Type F and fill to crosshatched area of dipstick Tighten cap screws to specification Torque Specification e Cap Screws 16 22 Nem 144 192 Ib in 4WD Output Disassembly A 4WD Front Cover B 4WD Gear Case C Shift Arm 4WD D Seal E Bearing F Bolt G Shaft Shift 4WD H Bolt Bolt 12 mm J Gasket K O ring L Spring Pin M Spring Pin N Shaft Front Drive O Arm Shift 4WD P Block Shift Bearing Q Collar Front Shift R Gear 4WD S Shaft 4WD T Collar Tuff Torq K92 Hydrostatic Transaxle 4WD Output Disassembly continued U Bearing V Snap Ring
25. e transaxle Fig 50 4WD Cover Removal Fig 48 4WD Cover Removal 18 From the 4WD gear case B remove 2 bolts with wash 14 Slide the 4WD shift shaft G down into the cover until ers AG and Al Remove 2 bolts H and 1 bolt with bearing shift block P is clear of the front shift collar Q washer AL and Al Fig 51 Remove the bearing shift block then pull out the front 19 Remove 4WD gear case from motor case assembly shift collar Q and 4WD output shaft N Drive out roll pin M from 4WD shift arm O by aligning roll pin with open port in 4WD cover bolt I must be removed Replace if damaged or worn Fig 49 15 Remove 4WD shift arm from 4WD shift shaft by pulling shaft up from the 4WD cover Fig 51 4WD Cover Removal 20 Measure OD of bearing surface If not within specifica tions replace front wheel drive output shaft NOTE Replace seal D if output shaft is removed Fig 50 25 4WD Output Disassembly and Assembly continued 21 Measure ID of pilot hole If not within specifications replace 4WD output shaft 22 Inspect sleeve on 4WD output shaft N for wear Re place as necessary 23 Inspect splines on 4WD output shaft N and shift collar Q for damage Replace as required Fig 52 24 Inspect groove in shift collar Q for scoring or damage Replace as required Specifications for 4WD Output Shaft e OD at Bearing 24 98 25 0 mm 0 983 0 984 in
26. eedle Bearing T Snap Ring U PTO Idler Gear 12 Tuff Torq K92 Hydrostatic Transaxle Installing 1 Clean mating surfaces of rear case and transaxle case Be sure threaded holes are clean Fig 23 2 Apply petroleum jelly to seal on shaft of PTO clutch as sembly E Fig 22 3 Apply a bead of silicon sealant to rear case mating sur face Fig 23 IMPORTANT Avoid damage Be sure rear case is aligned with transaxle case and installed within 4 mm 1 8 in of case before tightening cap screws Major damage can occur to PTO case and or transaxle case if not installed properly be fore tightening cap screws 4 Carefully position the rear case A on the transaxle and onto the lower dowel pin H Use a pry bar between the PTO and frame to carefully move the PTO approximately 1 5 mm 1 16 in to the right to align the top of the case with the upper dowel pin G Secure with 14 cap screws E Fig 24 Rear Cover Cap Screw Torque Specifications e Used Transaxle Case 25 Nem 18 lb ft e New Transaxle Case 30 Nem 22 Ib ft e Internal Cap Screws 27 Nem 20 Ib ft 5 Apply a bead of silicon sealant to PTO gear case A mat ing surface 6 Carefully position the PTO cover B on the PTO case A Align the top of the cover with the upper dowel pin F and onto the lower dowel pin I Secure with 3 cap screws C and 10 cap screws D Fig 24 IMPORTA
27. en the two sets of valve passageways all sia i Control Valve p i H _ Reverse Control Valve u 1 i T l 9 al T i Fi d er d l als O Y i 5 TA E u ER Fig 6 Control Valve Location PTO Solenoid Valve Removal and Installation IMPORTANT Avoid damage Do not bend twist or damage solenoid armature Do not damage machined sur faces or sharp edges of spool or sleeve PTO will not function or will function erratically if spool sleeve or armature is dam aged p di J ap T Fig 7 Charge Pump Rotor Tuff Torq K92 Hydrostatic Transaxle 1 Disconnect solenoid connector F from wiring harness A Wave Washer 10 2 B Spool 2 Remove nut A and O ring B Fig 8 C Sleeve D O ring E Flats F Solenoid Armature G Gasket H Large Land on Sleeve Oil Hole J Spring Fig 8 Solenoid Coil Disassembly 1 Disassemble PTO solenoid valve 2 Inspect parts for wear or damage 3 Remove solenoid cover C O ring D and solenoid coil E Note order and direction of valve components for reassembly 3 Install spool into sleeve so the end with the oil hole is toward the large land on the sleeve 4 Place spring into recess in end of spool 4 Remove solenoid armature assembly Fig 9 5 Install sleeve assembly so smaller lands go into the PTO 5 Carefully remove valve components from PTO cover cover first NOTE Check bottom of bore for wave washe
28. ential holder and carrier with Fig 39 the deeper offset of gear center away from the holder 8 Inspect ball bearings A and D for smooth rotation T Meet IAD aana ASEEN aaas Ibft Fig 39 11 Install differential lock collar N and left and right bear NOTE Final pinion shaft C and final gear F must be re ings O Push bearing tight against shoulder of differen placed as a set Bevel input gear B and bevel input pinion tial holder Fig 39 not shown must be replaced as a set 12 Install remaining components 9 Check bevel input gear B and final pinion shaft C for worn or damaged condition Replace parts as necessary NOTE Use medium strength thread lock and sealer Fig 39 Differential 4WD Disassembly and Assembly k I s oe E np 9 ac Fig 40 Differential 4WD Disassembly A Ball Bearing Washer 2 used B Bevel Input Gear J Pinion Gear 2 used C Final Pinion Shaft K Differential Pinion Shaft D Ball Bearing L Left Notched Differential Gear E Ball Bearing 2 used M Final Gear F Differential Holder Right N Differential Holder Left G Liner 2 used O Washers 8 used H Right Differential Gear P Cap Screws 8 used Q Differential Lock Collar 21 Differential 4WD Disassembly and Assembly continued 1 Use a puller to remove ball bearings E from differential NOTE Final pinion shaft C and final gear M must be re holders F and
29. hten to specification below Fig 71 Transaxle Case Cap Screw Torque Specifications e Used Transaxle Case 25 Nem 18 Ib ft e New Transaxle Case 30 Nem 22 Ib ft 7 Assemble bearing washers and snap rings on input Shaft Fig 73 With Rear PTO Option Assembly 8 Install input shaft assembly and large snap ring 40 Tuff Torq K92 Hydrostatic Transaxle 9 Install PTO brake shoe D and PTO clutch assembly C 13 Install axle housings Fig 74 See PTO Brake Removal and Installation on page 6 Fig 72 10 Install PTO idler shaft assembly E PTO gear F or rear PTO gear on rear PTO option units and snap ring G 11 Install PTO drive train See PTO Drive Train Mid and Rear PTO Removal and Installation on page 11 14 Install hydrostatic transmission and pump 15 Install control arm damper See Control Arm and Damper Removal and Installation on page 1 12 Install brakes See Brakes Removal and Installation on page 43 Rear Axle Assembly Removal and Installation Fig 74 Axle Disassembly A Shaft IMPORTANT Note position of two locator bushings J when removing axle housing B Snap Ring S C Sleeve 1 Remove six cap screws l holding axle housing to transaxle housing and remove axle assembly Fig 74 ae 2 Clean axle housing and transaxle mating surfaces Apply E Ball Bearing a bead of silicon sealant to mating surface
30. ially set Control pedal linkage bent binding or disconnected Directional control valves leaking or stuck down Directional valve in wrong location Anti cavitation valves leaking or stuck open Pump or motor valve plates scored or worn 999944 Too aggressive in reverse Free wheeling linkage set for push or partially set Linkage damper shock absorber failed Directional control valves leaking or stuck down Pump or motor valve plates scored or worn AA A A Slow forward under load or speed drops when load is applied Forward pedal height needs to be adjusted Free wheeling linkage set for push or partially set Control pedal linkage bent binding or disconnected Directional control valves leaking or stuck down Drive shaft not turning pump input shaft or charge pump key sheared Anti cavitation valves leaking or stuck open Directional valve in wrong location Charge pump scored or worn Pump or motor valve plates scored or worn Filter plugged or suction side air leak Check filter charge pump or case seal Engine performance is poor or not operating or set at correct operating speeds 99999 090909094 46 Erratic speed Free wheeling linkage set for push or partially set Linkage damper shock absorber failed Control pedal linkage bent binding or disconnected Brakes set or not releasing Directional control valves leaking or stuck down Drive shaft not turning pump input shaft or charge pump key sheared Anti cavitation val
31. ined surface When the scratches can be detected by feel using a lead pencil or fingernail the part must be replaced 11 Assemble parts in reverse order of removal 4 Check valve plate and cylinder block for grooves scor NOTE Use petroleum jelly to hold valve plate in position ing discoloration or pitting Put motor valve plate L on center valve block Make sure bronze surface is away from valve block and notch in valve 5 Check for free movement of pistons in cylinder bore plate fits on locating pin of valve block 6 Check pistons for flat areas scoring or discoloration IMPORTANT Avoid damage Apply clean hydraulic oil to all 7 Thrust bearing V must rotate freely Fig 55 mating surfaces NOTE Thin thrust plate X bushing W and motor case G IMPORTANT Avoid damage Pump and motor valve plates must be replaced as a set Fig 55 are not interchangeable The pump valve plate has two lead ing grooves into two of the slotted ports The motor valve 8 Inspect thin thrust washer for wear or damage Replace plate L has no leading grooves as necessary IMPORTANT Avoid damage Do not damage ball bearing NOTE Motor case will seem springy because the springs in F when removing seal cap B side the cylinder block are being compressed 9 Remove seal cap B and snap ring C to remove shaft assembly components 10 Inspect bushing W thrust bearing V and shaft I for wear or damage Replace if neces
32. ing D if ring is distorted during removal Fig 58 Hydrostatic 2 WD Motor 1 Secure motor housing assembly A and gasket F to center valve block B with 2 lower capscrews G In Stall ball bearing C and bevel input pinion E secure with retaining ring D Tuff Torq K92 Hydrostatic Transaxle Hydrostatic Transmission Installation IMPORTANT Avoid damage Do not drop or damage pump He allge ren A valve plate when removing center valve block assembly Do 2 Install center valve block B and motor assembly to not nick or scratch lapped or machined surfaces of the valve transaxle housing and secure with cap screws A plates or cylinder block components The slightest damage Fig 59 can cause poor performance e Tighten cap screws A to 39 Nem 29 Ib ft 3 Install charge pump See Charge Pump Removal and Installation on page 2 Fig 59 Hydrostatic 2WD 4WD similar Motor Install Hydrostatic Pump Inspection Fig 60 Hydrostatic Pump Disassembly 35 Hydrostatic Pump Inspection continued A Washers B Piston Spring 7 used C Snap Ring D Cylinder Block E Washer F Spring G Piston 7 used H Thick Thrust Plate Thrust Bearing J Thin Thrust Plate IMPORTANT Avoid damage Keep pistons matched with bore of cylinder block Do not interchange motor pistons and valve plate with pump pistons and valve plate Pistons and cylinder blocks are a matched set
33. ll new needle bearing F from inside case with bearing identification marks toward the inside of the case Push bearing tight against shoulder in bore Fig 20 Install new seal E with the open spring side towards the inside of the case Fig 20 Push seal against shoulder in bore Install mid mount PTO gear K so side with the longer center hub is towards bearing Fig 20 Clean mating surfaces of rear cover and case Be sure threaded holes are clean and two O rings are in position in rear cover Apply petroleum jelly to seal on shaft of PTO clutch as sembly Apply a bead of silicon sealant to cover mating surface IMPORTANT Avoid damage Be sure rear cover is aligned with transaxle case and installed within 4 mm 1 8 in of case before tightening cap screws Major damage can occur to cover and or case if cover is not installed properly before tightening cap screws Install transaxle drain plug Refill transaxle with ap proximately 9 0L 9 5 qt using ATF Type F as required to crosshatched area of dipstick Rear Cover Cap Screw Torque Specifications e Used Transaxle Case 25 Nem 18 lb ft e New Transaxle Case 30 Nem 22 Ib ft s Internal Cap Screws 27 Nem 20 Ib ft Tuff Torq K92 Hydrostatic Transaxle PTO Drive Train Mid and Rear PTO Remov al and Installation 1 bs 4 3 6 NOTE Approximate capacity of hydrostatic power train is 7 5L
34. n original holes as removed 3 Remove PTO drive gear G Inspect parts and replace as necessary Fig 26 4 Remove and replace oil seal S from cover Install new seal into cover with the closed side of the seal into the bore first Use a disk driver to push seal to bottom of bore Fig 26 Fig 27 Rear PTO Gear Case Assembly 14 Tuff Torq K92 Hydrostatic Transaxle 3 Remove shift collar F and shifter fork N assembly together Fig 27 NOTE If shift collar replacement is necessary the rear PTO idler gear and rear PTO input gear must be replaced also The three gears are available as a set 4 Remove tow relief valve L if necessary Remove and replace O ring Fig 28 Doo Dih Ca Bleed Fig 28 Tow Relief Valve 5 Remove 10 cap screws AC and removal PTO rear case from transmission case Fig 29 Fig 29 Rear PIO Gear Case Removal If shifter fork N see fig 27 was disassembled install spring Y and ball V in fork While compressing ball and spring install fork shaft CC Be sure ball fits into grooves of shaft Fig 37 15 7 With fork groove of shift collar away from case install shifter fork and collar Be sure arm of shifter shaft E fits into slot of shifter fork Fig 37 NOTE Install bearings with writing numbers facing gears in cover assembly 8 Using a rubber mallet tap the opposite side of the PTO cover to unseat the idler gear bea
35. nsaxle 2 Remove two 2 short A and one long Y cap screw Fig 3 Charge Pump Disassembly and Assembly Fig 3 Charge Pump Disassembly 2 Tuff Torq K92 Hydrostatic Transaxle Charge Pump Disassembly and Assembly continued A Cap Screw 2 used M10 x 65 6 Check small orifice in reducing valve S spool for obstruction B Plug C O ring 7 Replace parts if necessary D Pump Body 8 Remove plug H to remove charge pressure relief valve parts E F G and Fig 3 E Pressure Valve l 9 Inspect parts for scoring wear or damage d ue 10 Replace parts if necessary eng 11 Inspect seal X and bushing W for wear or damage lg 12 If bushing is removed apply clean hydraulic oil to Shims bushing and use a disk driver to install bushing to bot tom of bore J Pin K O rin 13 If seal is replaced apply clean hydraulic oil to new seal J Install seal with open side into pump body Push seal to L O ring bottom of bore M O ring 14 Apply clean hydraulic oil to all machined surfaces before N Outer Rotor Rm O Key NOTE Installation is done in the reverse order of removal P Inner Rotor Q O ring R Plug S Reducing Valve T Spring U Reducing Plug V O ring W Bushing X Seal Y Cap Screw M10 x 105 NOTE Charge pressure control valve and pressure reducing valve can be removed when the charge pump is in the machine To inspect valve seats and bores
36. p ring mm 1 3 16 in to push sleeve and washer tight against l shoulder of shaft IMPORTANT Avoid damage Do not use excessive force to l l install axle shaft Axle housing may be cracked or damaged if IMPORTANT Avoid damage Do not use excessive force to too much force is used install axle shaft Axle housing may be cracked or damaged if too much force is used 42 Brakes Removal and Installation Tuff Torq K92 Hydrostatic Transaxle A Snap Ring B Brake Actuator Plate C Friction Plate D Steel Plate E Steel Ball F Clevis Pin G Washer H Spring Lock Pin O ring J Interlock Plate K Cotter Pin L Washer M Rod N Adjustment Nut O Nut P Rod Fig 78 Brake Disassembly 43 Q Cam Lever R Brake Cover S Cap Screw 1 Inspect components on brake cover R Replace as nec essary Apply petroleum jelly to O ring Fig 78 2 Inspect plates for wear or spline damage If groove pat tern in friction plates is no longer visible replace plates 3 Apply petroleum jelly to balls E and install balls in cover 4 Install steel plates D and friction plates C alternately beginning with a steel plate 5 Apply a bead of silicon sealant to brake cover mating surface of transaxle case 6 Install brake actuator plate B and brake cover assembly R Brake Cover Cap Screw Torque Specifications Used Transaxle Case 25 Nem 18 Ib ft New Transaxle Ca
37. parts as necessary Fig 38 NOTE Installation is done in the reverse order of removal 19 H Roll Pin Shift Collar J Cap Screw K Plate L Fulcrum Differential Lock M Washer N Cotter Pin O Seal NOTE Install long hub of fork towards transaxle CAUTION Avoid Injury Springs are under compression Carefully remove roll pin and release spring force slowly to prevent personal injury Differential 2WD Disassembly and Assembly Fig 39 Differential 2WD Disassembly A Ball Bearing N Differential Lock Collar B Bevel Input Gear O Left Ball Bearing C Final Pinion Shaft 1 Use a puller to remove left ball bearing from differential D Ball Bearing nolder E Right Ball Bearing 2 Inspect differential components 3 Bearings must rotate free and smoothly Replace as necessary F Final Gear G Right Differential Gear 4 Check differential components for wear or damage If H Differential Carrier replacement is necessary all parts must be replaced as set Pins 2 used 5 Inspect differential lock collar for wear or loose or J Pinion Gear 2 used sheared off pins BoE ei NONE Pile nan ced 6 Check differential holder L and carrier H for wear L Differential Holder cracks or damage Fig 39 M Cap Screws w Washers 8 used 20 Tuff Torq K92 Hydrostatic Transaxle 7 Inspect final gear F for worn or damaged teeth 10 Install final gear on differ
38. pect anti cavitation valve assemblies NOTE Screens may be located in bores of transaxle case 6 Check suction screens for blockage 7 Carefully pull anti cavitation valve body from center valve block so as not to lose parts 8 Replace parts as necessary 9 Apply oil to O rings and push assembly to bottom of bore Inspect center valve block where charge pump contacts block for scoring 11 Replace center valve block if necessary NOTE Scoring is fine scratches or grooves cut into the highly machined surface When the scratches can be detected by feel using a lead pencil or fingernail the part must be replaced 34 12 Inspect valve plate for grooves scoring discoloration or pitting IMPORTANT Avoid damage Pump and motor valve plates are not interchangeable The pump valve plate has two lead ing grooves into two of the slotted ports The motor valve plate has no leading grooves 13 Put pump valve plate on center valve block Make sure bronze surface is away from valve block and notch in valve plate fits on locating pin of valve block NOTE Use petroleum jelly to hold valve plate in position 14 Remove plug to inspect charge pressure relief valve parts 15 16 Check plunger for nicks wear or damage Inspect plunger seat in center valve block Remove any obstructions and replace center valve block if seat is worn or damaged Hydrostatic Transmission Motor Installation NOTE Replace retaining r
39. ption Remove PTO brake shoe B and clutch A See PTO Brake Removal and Installation on page 6 Remove large snap ring H and input shaft assembly Remove large snap ring L small snap rings G and K washers M and J and ball bearing I from input shaft F Fig 63 Tuff Torq K92 Hydrostatic Transaxle Transaxle Disassembly continued F Input Shaft G Snap Ring H Snap Ring Ball Bearing J Washer mh K Snap Ring Ww y L Snap Ring M Washer Fig 63 Transaxle Input Shaft Disassembly 9 Lay transaxle on left side and remove sixteen 16 cap IMPORTANT Avoid damage Bearing washer and differen screws N attaching right cover assembly O tial pinion located on top of differential assembly are loose Do not drop or lose parts Fig 65 Final Pinon Gear 11 Lift final gear and differential assembly and differential lock shaft from transaxle case together as an assembly Fig 64 Right Transaxle Cover 12 Remove final pinion shaft assembly Fig 65 10 Remove final pinion shaft ball bearing Bearing may remain in cover assembly 37 Transaxle Right Cover Disassembly and Assembly Fig 66 Transaxle Right Cover Disassembly A Swash Plate Bearing Q Fulcrum Cap Screw B Washer 1 Remove nut H washer I and snap ring F Fig 66 C Bushing 2 Pull swash plate from cover E D Spring NOTE Pump swash plate bushing and thin thrust plate
40. r J Snap Ring K Input Shaft Collar L Snap Ring M Thick Steel Plate N Friction Plate O Spring P Pin Q Steel Plate R Clutch Gear Hub S Washer T Seal Ring 1 Remove PTO clutch assembly See PTO Brake Removal and Installation on page 6 2 Remove large snap ring and thick steel plate 3 Remove parts NOTE Friction plates springs steel plates and pins must be replaced as a set 4 Replace clutch gear hub if brake surface is badly scored or teeth are chipped or damaged 5 Remove piston from clutch gear hub Use a transmis sion gear spacer X to compress spring U and washer V in a vise Remove snap ring W and slowly release force of spring Fig 42 Remove remaining clutch parts Check bearings for smooth rotation Inspect clutch gear for worn or damaged teeth G O N g Check inner piston bore for scoring or wear Tuff Torq K92 Hydrostatic Transaxle 23 Fig 42 Clutch Disassembly Check steel plates for scoring discoloration warping or wear Replace worn or damaged springs Check input shaft collar for burrs wear or damaged teeth or splines Check clutch pack wear Assemble parts Fig 43 Clutch Disassembly Put clutch gear hub on bench so steel and friction plates are against snap ring Measure clearance between inner steel plate and bottom of clutch gear hub 15 If clearance measures 2 7 mm 0 106 in or more re place PTO clu
41. r 6 Install gasket and O ring 6 Clean and inspect parts for damage Replace if neces Sary 7 Place wave washer in case cover Disassembly Inspection and Assembly NOTE Sleeve and spool must be replaced as a set IMPORTANT Avoid damage Be sure large land H on sleeve and oil hole in spool are facing away from PTO case cover Fig 10 Solenoid Coil 7 Tighten solenoid armature to 22 Nem 195 Ib in 8 Slide solenoid coil M onto solenoid armature Install O ring L and plastic nut N do not tighten plastic nut at this time Fig 10 Fig 9 PTO Solenoid Armature Disassembly 9 Position solenoid coil wire leads P to the right and approximately 45 above horizontal IMPORTANT Avoid damage When tightening plastic nut be sure to tighten nut to exact specifications Nut has a very low torque Any overtightening will damage the armature coil Fig I I PTO Electrical Solenoid PTO Relief Valve Removal and Installation PTO Relief Valve Disassembly Inspection and Assembly Fig 13 Relief Valve Assembly 1 Disassemble PTO relief valve Fig 13 2 Check relief valve plunger and bore for scoring nicks or burrs Replace if necessary 3 Install spring B gasket C relief valve plunger A and plug D in PTO cover Fig 13 PTO Brake Removal and Installation NOTE Approximate capacity of hydrostatic power train is 7 5L 7 9 qt for 2WD and 7 8L 8 2 gt for 4WD and 9 0L 9 5
42. re 9994 PTO will not stay engaged Check engagement solenoid circuit Engagement valve installed incorrectly PTO clutch piston leaking input shaft seal leaking or clutch disk worn 47 PTO will not stay engaged continued LOW charge pump output PTO pressure control valve faulty Gear or bearing noise with PTO engaged PTO brake is not releasing Check brake piston O rings PTO brake springs faulty PTO shaft slows down Excessive load on PTO output Remove load Use higher engine rom Check engine performance PTO lube reduction valve orifice plugged Low charge pump output PTO pressure control valve faulty PTO clutch piston leaking input shaft seal leaking or clutch disk worn 999044 PTO Shaft will not stop or slow to stop Check engagement solenoid circuit Engagement valve installed incorrectly PTO brake is not releasing Check brake piston O rings Excessive load on PTO output Remove load PTO brake springs faulty 9 99 Transaxle Engagement Problems Hydraulic transmission complaint Brakes are applied or mis adjusted Rear drive wheels are locked up will not move directional pins down Brakes are applied or mis adjusted Differential lock collar pin or differential carrier fail ure Check axle or differential gear failure Rear wheel free wheel no transaxle drive hydraulic control valve pins are up Check axle or differential gear failure Differential lock
43. rings and shaft as a single item Fig 30 Fig 30 Idler Gear Set 9 From reverse side of PTO case drive out the PTO idler pinion gear PTO input gear idle shaft and bearings from their seated position as a single item Press bear ings from shaft and inspect all components for wear or damage replace as necessary Fig 31 Fig 31 Input Gear Set 10 From reverse side of the PTO case drive out the rear PTO shaft PTO gear and bearings from case as a single item Fig 32 Rear PTO Removal and Installation continued 13 Remove snap ring L idler gear G snap ring H press bearing I and press bearing K from shaft J Inspect all components for wear or damage replace as neces sary Fig 35 NOTE Recall writing numbers on all outer bearing races and install bearings in reverse order as removal Fig 32 Rear PTO Shaft Assembly 11 Remove press bearing S from the PTO shaft X then remove PTO gear T snap rings Z and press bearing W from PTO shaft Inspect all components for wear or damage replace as necessary Fig 33 Fig 35 Rear PTO Idler Gear Disassembly 14 If necessary remove ball switch W and O ring Fig 36 e If removed install O rings and ball switches W DO NOT overtighten Tighten to 34 Nem 25 lb ft Fig 33 Rear PTO Shaft Disassembly 12 Remove press bearing M from idler shaft P Remove washer N PTO input gear R and idler pinion gear
44. rive Train Mid PTO Removal and Installation 9 PTO Drive Train Mid and Rear PTO Removal and Installation 11 PTO Relief Valve Disassembly Inspection and Assembly 0 00 6 PTO Relief Valve Removal and Installation 2222200222400000000 Benno 6 PTO Solenoid AS stasis es ae ne are a ee ar ee 4 Rear Axle Assembly Disassembly and Assembly eee eee eee 42 Rear Axle Assembly Removal and Installation sees eee 41 Rear OS SS ON arate aes setts eect ee re een 17 Rear PTO Removal and Installation een ae 14 Recommended Tools and Equipment 22200240020000000 0000 nnnn anne anne nenn IV Serial Number LOCA on ee IV Transaxle Right Cover Disassembly and Assembly eee eee e 38 Transaxle RI nle U 36 Troubleshooting GUIdES cn een 46 Ordering Replacement Parts Online W W W J TUFF TORR PRODUCTS L MAETH oi LS Wook e SE ie BEH DEP dT ESA FS Home DRIVING TOUR BEST IDEAS ch TORR AT LH pii bene Te Amr Tae Bel we Meeting the Herda of DEM Cuniomers DRIVING TOUR BEST IDEAS k Ti a el es PERE 8 K ee a ee LA f ee Pe ee l lt TUT TEN PEA h EEEE an FH nei 4 See N pa m Cn ee i PIS a a NEST K 8 6 I eaer r ele 2 ee en ee ee l b Prep eee pra eh EDER PER ee a dr Pe r I ig 69 ye eB L ea aya u Rr on RR E R me ne mr
45. sary Fig 55 30 Tuff Torq K92 Hydrostatic Transaxle Hydrostatic Transmission Motor Disassembly and Assembly 4WD Fig 56 Hydrostatic Transmission Motor Disassembly 4WD A Cap Screw 2 pieces R Gasket B Snap Ring S Thick Thrust Plate C Snap Ring T Thrust Bearing D Ball Bearing U Bushing E Motor Case V Thin Thrust Plate F Locating Sleeve 2 used 1 Remove 4WD gear box assembly See 4WD Output G Motor Shaft Disassembly and Assembly on page 24 H Center Valve Block Assembly IMPORTANT Avoid damage Do not drop or damage mo on tor valve plate when removing motor assembly Do not nick Locating Pin or scratch lapped or machined surfaces of the valve plate or je atar Valve Plate cylinder block components The slightest damage can cause poor performance K Snap Ring 2 Remove two cap screws A Fig 56 L Washer M Spring IMPORTANT Avoid damage Keep pistons Q matched with bore of cylinder block N Do not interchange motor pistons N Cylinder Block and valve plate J with pump pistons and valve plate Pistons ETER and cylinder blocks are a matched set P Piston Spring 3 Remove cylinder block assembly Q Piston NOTE Motor rotating components must be replaced as a set 31 Hydrostatic Transmission Motor Disassembly and Assembly 4WD continued 4 Inspect rotating components NOTE Scoring is fine scratches or grooves cut into the highly machined s
46. se 30 Nem 22 Ib ft Hydrostatic Flow Diagram Check Points O PTO Pressure Test Port 2 PTO Pressure Test Port 1 PTO Pressure Control Valve 8 9 PTO Electrical Engagement Solenoid Fig 79 Check Points Rear PTO Relief Check Tow Valve Forward Implement Relief Valve Charge Pressure Control Valve Pressure Reduction Valve Fig 80 Check Points Charge Pump Center Valve 44 Tuff Torg K92 Hydrostatic Transaxle KR KK KK KK i i ir i re nn PTO Clutch PTO Pressure Test Port 2 10 Reading gt 1500 kPa I A ANAA gt 218 psi L PTO Electrical Engagement Solenoid K92 Transaxle Hydraulic Th wa a Flow Diagram Laa A Transaxle Case an 8 PTO Pressure Control Valve x 1750 250 kPa 254 36 psi MN N 1 5 1 8 L min 0 40 0 48 gal min PTO Brake PTO Pressure Test Port 1 2 Reading gt 1500 kPa I gt 218 psi i na Anti Cavitation Eu ee Gee Check Valve 1 7 Oc 7 I oes I I 31600 1500 kPa Anti Cavitation 4583 218 psi Screen i E ES L J 2 I _ I I Implement I ka L 995 72 psi i Tow Valve Forward I i I Pressure l 1 Hydrostatic Variable r Reduction Hydrostatic Fixed i Displacement Pump Valve ee Displacement Motor i E 690 200 kPa I Charge Pump N 100 29 psi I 18 cc rev 18 cc rev 0 8002Irev gt gt 0 8002Irev Gear Room 5 1
47. ston J Cover K Cap Screw 3 used L O ring M PTO Brake Shoe N PTO Clutch Assembly 1 2 3 4 Carefully pull piston assembly from case using a pliers Do not damage pin Fig 7 Remove PTO clutch assembly N and brake shoe M together NOTE PTO brake pin piston springs and O rings etc parts C thru I must be replaced as a set Check pin and piston for burrs scoring or wear Replace brake shoe if grooves in shoe contact surface are not visible Inspect O rings for cuts or damage Inspect springs for cracks or damage Apply petroleum jelly to O rings and seal on end of PTO clutch shaft Install piston assembly and clutch assembly Clean mating surface of side cover and transaxle case Be sure threaded holes are clean 10 Apply a bead of silicon sealant to cover mating of sur face IMPORTANT Avoid damage Be sure side cover is aligned with transaxle case and installed within 3 mm 1 8 in of case before tightening cap screws Major damage can occur to cover and or case if cover is not installed properly before tightening cap screws Transaxle Cover Cap Screw Torque Specifications e Used Transaxle Case 25 Nem 18 lb ft e New Transaxle Case 30 Nem 22 Ib ft PTO Drive Train Mid PTO Removal and Installation NOTE Approximate capacity of hydrostatic power train is 7 5L 7 9 gt for 2WD and 7 8L 8 2 gt for 4WD and 9 0L 9 5 gt for 4WD w
48. tch plates 16 Apply clean hydraulic oil to all parts NOTE Installation is done in the reverse order of removal 4WD Output Disassembly and Assembly 1 Drain transaxle 6 Remove the first press bearing E gear Y washer Z and gear AA from 4WD reduction shaft X Remove 4WD reduction shaft X and the second press bearing E from the 4WD gear box as a single item Fig 46 CAUTION Avoid Injury Allow transaxle to cool before drain ing fluid Hot fluid can cause serious burns 2 Remove bolt washer I J and drain the 4WD gear box 7 Remove press bearing E from 4WD reduction shaft X 3 11 bolts H bolt AK and bolt AH from 4WD NOTE When reinstalling take care to place gears in their original order with the thicker gear in front with raised sur 4 Remove 4WD cover A face towards the bearing and the thinner gear behind NOTE To avoid damage during separation to the cover and or the gear box use the pry points shown in fig 44 Fig 46 4WD Cover Removal 8 Remove snap rings V and AM then gear R from shaft S Remove snap ring AN and remove S T U V W and AO as a single item from the 4WD gear case Fig 44 4WD Cover Removal 9 Remove press bearing AO collar W snap ring V press bearing U and collar T from shaft S Fig 47 oy BEMOVEINEOLIVE aan rom motor snart NOTE Flat end of shift collar goes toward bearing 10 Clean bearings in
49. th the open spring side towards the else 10 Inspect swash plate bearing G for wear or damage Replace if necessary vaa alaa MAOS 11 Install new bearing using a disk driver Push bearing to bottom of bore 12 Inspect vent cap F for damage or obstructions Replace as necessary Transaxle Assembly Fig 68 Differential Shaft Port 5 Replace differential lock shaft seal C Fig 68 NOTE Differential lock plate D may have to be removed to install new seal 6 Install new seal with the open spring side towards inside of case Push seal tight against bottom of bore Fig 70 Final Pinon Gear 1 Apply clean hydraulic oil to all internal components 2 Install final pinion shaft assembly into transaxle case with bevel gear end in first 39 IMPORTANT Avoid damage Bearing and washer on top of differential assembly are loose Do not drop or lose parts 3 Put fork of differential lock shaft into groove of collar on differential assembly Install differential assembly and differential lock shaft together into transaxle case 4 Install ball bearing Fig 71 Transaxle Right Cover Assembly 5 Apply a bead of silicon sealant to mating surface of transaxle case 6 Carefully lower right transaxle cover assembly B onto case while making sure bearings and shafts fit into bores properly Make sure washer on swash plate does not fall out of position Secure with sixteen 16 cap screws A and tig
50. ump scored or worn 99 9994 Troubleshooting Guides Hydrostatic Transmission Problems continued Hydraulic noise continued Pump or motor valve plates scored or worn Filter plugged or suction side air leak Check filter charge pump or case seal Charge pressure relief valve leaking Seat valve or spring damaged Swash plate control shaft or bushing worn Gear noise dependent on speed direction of travel or during a turn Go through procedures in Hydrostatic Transmission Test for additional tests Brakes set or not releasing See Brakes section Drive shaft not turning pump input shaft or charge pump key sheared Charge pump scored or worn Pump or motor valve plates scored or worn Filter plugged or suction side air leak Check filter charge pump or case seal 99 Z Mid PTO Engagement Problems PTO will not engage Check engagement solenoid circuit PTO switch not working PTO lube reduction valve orifice plugged Engagement valve installed incorrectly PTO pressure control valve faulty PTO clutch piston leaking input shaft seal leaking or clutch disk worn Low charge pump output PTO shaft gear or bearing failure 9 999994 Engine stalls when PTO is engaged Excessive load on PTO output Remove load Use higher engine rpm Check engine performance Hydraulic circuit in relief Remove restriction or load PTO brake is not releasing Check brake piston O rings PTO shaft gear or bearing failu
51. ur equipment manufacturer or authorized dealer Select your brand from the Welcome page and you will be directed to the appropriate web site Navigating the web site To access Tuff Torq s web site type in www tufftorg com from your Internet browser From the Home page click on Service to enter the Online Ordering page Ref Page 1 From Ihe Online Ordering page click on Click here to enter service web site to enter the Welcome page Ref Page 2 From the Welcome page login for register users and follow the on screen instructions Or click on Catalog Order to enter Store Browser Ref Page 3 From the Catalog Order page select your transaxle model e g K61 Click on K61 to find the serial number for your model Ref Page 4 From the Model Series page click on your Model to enter the Serial Number Range page Ref Page 5 Tuff Torq K92 Hydrostatic Transaxle Furr TRR CATALOG t 614 ET r aigf kr Yoan Tem le West Caialeg browser Fie Seeker Y ut aad uns Ait ee ee KRIL OETI HE a b pan drip RR 8 EMA a b reer an re L gir Tr Ese SP oh T L Tiei om Lang bis me N ge chee FRE b Lemmer k 4 b rare s ved oe ca i ea nn r Psa eal En i PRS Le a li d ai Bs a ibe ie Tim R Tes 3 a ii i T pms ME a miil cd T er ma m im rd Rea TT a RIR E 81 Remi T em i Page 6 7 bone EIL VE E Pre dect HH
52. urface When the scratches can be detected by feel using a lead pencil or fingernail the part must be replaced 5 Check valve plate and cylinder block for grooves scor ing discoloration or pitting 6 Check for free movement of pistons in cylinder bore 7 Check pistons for flat areas scoring or discoloration 8 Thrust bearing T must rotate freely Fig 56 NOTE Thin thrust plate V bushing U and motor case E must be replaced as a set Fig 56 9 Inspect thin thrust plate V for wear or damage Re place as necessary IMPORTANT Avoid damage Do not damage ball bearing D when removing snap ring B 32 10 Remove snap ring B to remove shaft assembly compo nents 11 Inspect bushing U thrust bearing T and shaft G for wear or damage Replace if necessary Fig 56 IMPORTANT Avoid damage Apply clean hydraulic oil to all mating surfaces 12 Assemble parts in reverse order of removal NOTE Use petroleum jelly to hold valve plate in position Put motor valve plate J on center valve block Make sure bronze surface is away from valve block and notch in valve plate fits on locating pin of valve block IMPORTANT Avoid damage Pump and motor valve plates are not interchangeable The pump valve plate has two lead ing grooves into two of the slotted ports The motor valve plate J has no leading grooves NOTE Motor case will seem springy because the springs in side the cylinder block
53. ves leaking or stuck open Charge pump scored or worn Pump or motor valve plates scored or worn Filter plugged or suction side air leak Check filter charge pump or case seal Charge pressure relief valve leaking Seat valve or spring damaged Swash plate control shaft or bushing worn Engine performance is poor or not operating or set at correct operating speeds See Engine diagnosis 9999 ZZZ Machine will not stop Free wheeling linkage set for push or partially set Control pedal linkage bent binding or disconnected Brakes set or not releasing Neutral adjustment is not correct Anti cavitation valves leaking or stuck open Swash plate control shaft or bushing worn ZZ AAA Transmission operating hot Free wheeling linkage set for push or partially set Control pedal linkage bent binding or disconnected Brakes set or not releasing See Brakes section Neutral adjustment is not correct Oil cooler may be plugged with debris Directional control valves leaking or stuck down Anti cavitation valves leaking or stuck open Charge pump scored or worn Pump or motor valve plates scored or worn 979999944 Hydraulic noise Free wheeling linkage set for push or partially set Brakes set or not releasing See Brakes section Neutral adjustment is not correct Drive shaft not turning pump input shaft or charge pump key sheared Directional control valves leaking or stuck down Anti cavitation valves leaking or stuck open Charge p
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