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Tecumseh / Peerless Motion Drive System

1. ooo ooo De ILLUSTRATION 5 OLD STYLE NEW STYLE NOTE Reverse and first gear do nothave 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 Sour gears no longer have a recess on one side of the gears and do not require that the gear to be positioned in any particular direction Units that have less then 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 Illustration 5 When the final spur gear or Spacer is in place a thrust washer Is positioned on the shaft to protect the case from the rotating gear This washer is slightly larger then the diameter of the spacer and large enough to cover the inside diameter of the key slot portion of the shifter Spur gear Next place the bronze bushing and the oil seal on the shaft the open side of the seal must face inward this completes the spur gear side of the shifter brake shaft The output Side only requires the output Spur gear washer and bushing RETAINING CLIP ry NAH rs i wy TOWN REVERSE FOR B INPUT ILLUSTRATION 6 To assemble the countershaft place the re
2. e Use the authorized tool to install the new bearing Needle bearings in shifter shafts Should be installed 010 below flush D BUSHING SERVICE When removing bushings use the combined bushing remover and installation tool Position the piece to be serviced on the table of an arbor press with an opening to allow the bushing to pass through 1 Use the proper tool as illustrated 2 The bushings in the three gear cluster four Speed transaxle are both removed atthe same time The bushing from one end will contact the bushing in the opposite end and both may be pushed out 3 Use an arbor press and push the steel ball through the new bushing to expand it to the required size KIT 670254A Et 670270 Use with Seal with 13 16 I D Bushing with 3 4 I D Busing with 1 1 2 I D Seal with 1 2 I D Bearing with 5 8 I D Seal with 21 32 I D Bearing with 1 2 I D Seal with 1 2 I D Bearing with 9 16 I D Bearing with 5 8 I D Input Bearing on 800 Series Bearing with 11 16 D 800 Series 103
3. 1 Remove the hex head screws that hold the cover to the case 2 Push the shiftlever rod while pulling cover off the case The shifting lever may temporarily remain in the case Lift off cover 3 Remove the two brake bracket screws and remove brake assembly 4 Remove the grease from the unitas the parts are removed Prior to removal of gear shaft assemblies from the case the shifter fan may be removed Note the position of the parts before removal Some parts may come off the shafts upon removal NOTE BENTONITE GREASE MAY STAIN CLOTHES CARE SHOULD BE USED WHEN HANDLING 5 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 41 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT O RING BEVEL GEAR 42 SSS L135 eee 150 THRUST RETAINING RING WASHER 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 partNo 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 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
4. INPUT SHAFT Input shaft removal same for 700 series in line and H shift pattern transmissions 3 Remove snap ring from input shaft remove bevel gear and pull shaft through case 4 Inputshaftneedle bearings should be installed flush to 005 below bearing bore surfaces from inside and outside case C INSPECTION AND REPAIR Examine all parts after removing grease with cleaning 18 solvent Replace damaged parts tan menu D ASSEMBLY OF 700 SERIES H SHIFT PATTERN TOT OUTPUT AND BRAKE SHAFT Same as 700 series in line except for additional collar and spacer ASSEMBLY OF 700 SERIES H SHIFT PATTERN SHOULER 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 Same as for 700 series in line transmission except for additional spacer NOTE The thrust washer on the shift gear end of the output shaft does not have a chamfer on the inside diameter and must be positioned as shown It is thicker than the other thrust washers separating the gearworks from the bearings CHAIN SPROCKET COLLAR OUTPUT SPROCKET i A Oy rr I i L a BUSHING BUSHING OUTPUT AND BRAKE SHAFT Correct assembly for 700 Model H shift pattern First second and third gears have to be forced over the key when assembling BEVEL SPUR GEAR
5. NOTE The axle and brake shaft seals on later production MST s have been redesigned to eliminate the need for sealantin the seal bearing pocket area These new Seals are identified by external ribs that hold the seal in place and prevent leakage DO NOT put sealant in the seal bearing pockets with this new type seal ILLUSTRATION 11 Before placing the cover on the case place the shift rod and fork pins into the shift collar and shaft into the boss in the case Inspect the shafton the rod and fork for rust and burrs Illustration 11 8 Place a coating of grease on the shaft for easy assembly and corrosion protection Replace an menu 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 Install the cover screws and torque them to 90 100 inch pounds Replace the index ball Spring and set screw Turn the setscrew down to the flush position Install the neutral start sensing switch if applicable Illustration 12 NOTE Do not forget to re install the bottom two bolts DETENT SCREW SPRING BALL Detent screw must have pipe thread sealant applied to prevent oil leakage ILLUSTRATION 12 9 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 t
6. in Ibs Differential Bolts 7 ft los 9 5 NM T Drive Bolt 8 11 ft Ibs 10 9 15 0 NM T Drive Cover Screw 20 24 in Ibs 2 24 3 7 NM ein menu f SECTION 5 TROUBLE SHOOTING TABLE THE FIRST RULE IN TRANSAXLE TROUBLE SHOOTING IS TO ISOLATE THE PROBLEM TO THE TRANSAXLE CHECK FOR PROPER ADJ USTMENT OF BELTS BRAKE CLUTCH SHIFTER AND LINKAGES CHECK PULLEYS FOR SHEARED RETAINERS AND PROPER BELT DISENGAGEMENT IF PROBLEM IS RELATED TO SHIFT DIFFICULTIES REMOVE DRIVE BELT AND RECHECK SHIFTING TO ASSURE PROBLEM IS NOT WITH ASSOCIATED EQUIPMENT All In Line Shift Models 700 800 900 or MST Series Shifting force or effort should be the same with the engine running or notrunning If notequal check the following area s clutch adjustment brake adjustment belt release and belt guide positioning The transaxle and transmission models listed above are in line shift mechanical gear drive models that use shift keys to engage a desired gear to lock and rotate with the shaft This type of unit requires the transaxle or transmission to be in a no load condition de clutched when gear selection occurs De clutching allows the unit to have the input and brake forces removed from the gears and shift keys which allows the unit to turn freely Improper shifting shifting while on an incline shifting while towing any type of load or shifting without de clutching forces the shift keys to engage into a gear that is in a loaded cond
7. REVERSE IDLER SHAFT BOSS LOW GEAR SHAFT BEARING MAGNETIC DRAIN PLUG BEARING TO BE 015 020 BELOW THRUST SURFACE 15 Remove input shaft from case by tapping with a non metallic hammer C INSPECTION AND REPAIR l Gears a Check bevels for evidence of galling due to improper shifting NOTE Peerless Transaxles must be stopped for shifting b Check face of teeth for wear Large shiny areas indicate too much tooth contact and possible excessive wear Replace gears indicating damage or excessive wear Shafts and Axles a Check surface for rust pitting scratches Or Wear b Check keyways splines threads and grooves for wear Replace parts if worn or damaged beyond a refinishable state 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 Thrust Washers and Spacers Check for shininess indicating wear Replace if wear Is evident Try to determine cause of thrust washer wear such as lack of end play due to reuse of gasket or use of wrong thrust washer Shifting Assembly Refer to the Chapter on shifting assemblies Gaskets Replace all gaskets Oil Seals It is a good habit to replace all seals It is necessary to replace all double lip seals See Chapter 1 paragraph F OIL LEAKS SEAL AND GASKET SERVICE Bearings and Bushings Refer
8. To seal outward single lip to prevent lubricant leaks To seal both inward and outward double lip Some Seals are spring loaded Thatis a spring creates a positive light compressing action to insure that the seal lip will make a 100 contact around the shaft All Peerless seals seal on the inner diameter l Other than leaking seals gaskets and O rings leakage can occur due to a cracked case or cover flats on shafts porosity rarely if ever and worn bushings and shafts Single lip inward sealing can be salvaged by the use of the proper seal protector when pulling the seal over a shaft Outward sealing seal both single and double lip must be replaced since there is no assurance that the initial sealing Surface can be protected If you can t protect the sealing lip replace the entire seal The cost of the seal is small in comparison to a return repair due to reuse for Seals Check seals for cracks scuffs cuts and distortion Check seal areas for evidence of oll leak both at sealing surface and between metal to metal contact surface areas Some seals have a Redicoat sealant applied while others may need a thin coat of this ora Similar sealant The surface over which the seal lips must slide must be free of all cuts scratches high spots or rust The shafts should be smooth shiny and a thin film of light oil applied Sleeves should be used to clear keyways splines or other Sharp edges machin
9. RIGHT HAND SHIFT ROD 27 COVER CASE HEX T SCREWS 17 D DISASSEMBLY Remove Hex screws that hold cover to case Push shift lever rod in while pulling cover off of case Shifting assembly may temporarily remain in case Remove cover NOTE Remove grease from the unitas parts are removed Remove two brake bracketscrews and remove brake assembly NOTE Prior to removal of gear shaftassemblies from the case the shifter fan may be removed It will be difficult to keep parts from falling off the assemblies Note position of parts before removal SHIFTER BRAKE SHAFT OIL SEAL a EE ER ee me G A AE miy i inf E C 7 HY l fit BH HEN ret i Sy SLT I P e NY BEARING BUSHING DIFFERENTIAL FLANGED COUNTER RETAINER BUSHING SHAFT ASSEMBLY 4 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 hubs on sprockets y NOTCH FLANGED SQUARE CUT BUSHING SHIFTER GEARS 7 oi SHIFTER BRAKE WASHER Puree 2 Hhe FLANGED JE g le i am Fe Eai ion me PP LODI i l Fil f SQUARE CUT SEAL PINION IN EACH END OF SPUR FLAT WASHER OUTPUT PINIOIN GEARS NOTE Before disassembly observe how V notches on the flanged bushings fitinto recess V of case NOTE The square cut black rubber O ring acts
10. SHAFT WITH MALLET TO SEPARATE k Using a soft mallet separate the input shaft and gear A slight press fitholds a spline surface on the shaftin a spline of the gear Remove and discard the output shaft oil seal Do notscratch shaft Remove and discard snap ring Tap the shaft into the housing using a soft mallet TO REMOVE GEAR REMOVE SNAP TO REMOVE BEARING TO ALLOW SHAFT AND REMOVE GEAR AND BEARING TO DROP OUT PRESS BEARING OF HOUSING INNER RACE If necessary remove the snap ring to separate the gear and bearing from the shaft Hold the gear and bearing in one hand and tap the end of the shaft vigorously with a soft mallet Cleaning Inspection and Repair a Clean all parts of grease rust or foreign matters b Dryall parts Compressed air may be used on all parts EXCEPT BEARINGS c Check bearings for smooth rotation Lubricate d Remove all burrs and scratches from shafts e Check housing for cracks or pulled metal f Replace allsnap rings removed g Replace all oil seals If Separated install inner ball bearing and bevel gear on output shaft Be careful of alignment Use ofa press is preferable to tapping parts together with a mallet mein menu 10 Press shaft bearing and gear assembly into housing until outer bearing race bottoms in retaining cavity 11 Install outer bearing and new snap ring USE THE PROPER SIZE SEAL PROTECTOR ALWAYS REPLACE OIL SEALS 1
11. Tecumseh part number 788067B tan menu E REASSEMBLY 1 Apply grease between the bearings in the cover and install the input shaft bevel gear and snap ring SHIFTER BRAKE SHAFT a COLLAR 2 Grease both keyways and slide keys and collar on shifter brake shaft BEVELED SIDE FLAT SIDE 3 The large beveled shifting gears can be placed onto the shifter orake shaft The bevels on the gears face each other and are separated with a neutral spacer Push shifting keys into the neutral spacer A thrust washer a bronze bushing and an O ring are then placed on the shaft The spur gear washer bushing and O ring are assembled to the other end of the shaft INY 4 Place the shifter orake shaft assembly in the case OUTPUT GEAR OUTPUT PINION 5 Place the output gear onto the output pinion Install the thrust washers and bushings LOWER BEARING BLOCK 6 Insertthe outputshaft assembly into the case 7 Prior to installing differential into case apply Bentonite grease to axle bearing surfaces 8 11 12 NOTE The differential must be assembled out of the case and then placed in the case Insert the lower bearing block into the case with the flange to the left 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
12. The open end bearing in the shifter shaft should be 010 below the end To remove the needle bearing in the splined shifter shaft proceed as follows NOTE Blind bearing pullers are available to remove this bearing There is a Space between the bottom of the drilled hole and the inside end of the bearing to accommodate the ridges of the bearing puller Tool No 670203 670204 670205 670206 670207A 670209 670210 670211 670213 670234 670251 670252 Frys Nad r l a DA PA ee ee i noo Heres cue eee Sm With the needle bearing up clamp the splined shifter shaft vertically in a soft jaw vise so that the lower end of the shaft rests on a block of wood Prepare some pieces of paper toweling newspaper etc by soaking in water Tear paper into pieces approximately one to two inches square Stuffthese wet pieces of paper into the needle bearings until full Inserta 7 16 metal rod into this bearing With a mallet strike the rod sharply this will compress the wet paper Continue to add more wet paper this will hydraulically lift the bearing out of the shaft PEERLESS TOOL 670211 Description Oil Seal Installer Bushing Driver and Installer Bushing Driver and Installer Oil Seal Protector Bearing Driver and Installer Oil Seal Installer Bearing Driver and Installer Oil Seal Installer Bearing Driver and Installer Bearing Driver and Installer Bearing Installer Bearing Driver
13. bevel gear next to the reverse sprocket mein menu SECTION 10 MST200 CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to many variations of the equipment braking systems adjustment and repair to the components and linkages are not considered warranty CUSTOM ER MOUNT POINTS PRY POINT A GENERAL The MST Manual Shift Transaxle 200 is a sealed unit which uses 16 oz of 80W90 gear lube part 730229A The MST series is available with up to 6 speeds forward and one reverse It has a sculptured case and cover Its unique gear design system uses the input gear to drive both the forward and reverse motion It also eliminates the recess previously found on shifter brake shaft spur gears The thrust washers on all transaxles are used to protect stationary surfaces from rotating surfaces To determine the location of the thrust washer check its inside diameter and compare it to the outside diameter of the shaft If the fit is loose it is out of position The flat washer used on the shifter shaft brake end must have a diameter large enough to stop the keys from going past the end of the gear slots gt IDENTIFICATION TAG IDE
14. down d Insert shifter assembly Check that rods are seated properly e Install reverse idler Make sure beveled edge is up Spacer on top of gear CENTER PLATE ASSEMBLY f Place new gasketon case and install center plate 25 DIFFERENTIAL ASSEMBLY SCREW FASTENERS ZA O INPUT SHAFT g Place new gasketon center plate and install differential assembly longer axle in down position Be sure gear on shifter shaft is on shaft SEAL PROTECTOR COVER DIFFERENTIAL TE ASSEMBLY ZS J i lt i F h Install gear case dowel pins Leave dowel pins slightly exposed on top to locate cover assembly Install cover assembly and Torque the cap screws to 7 9 ft lbs or 84 108 in Ibs i Ifunitneeds bearings or bushings installed consultthe Chapter for bearing and bushing service for proper procedures j Install axle supports and fill with S A E 80W90 part number 730229A gear lube Fill through shifter housing NEUTRAL POSITION k Inspection Note Fora neutral position shift notches in forks and notch in stop must be aligned and centrally located 14 Brake Lever Assembly The brake lever type is determined by the original equipment manufacturer s selection of this option ii mez r When assembling apply a lightfilm of lubriplate to the inside lever portion which contacts the pins also to outside of lever which contacts flatwasher and between shaftO D and bore of brake dis
15. when installing the 2500 in the equipment Lubrication for the 2500 is 7 to 8 pts SAE Type A automatic transmission fluid 2 PREPARATION FOR DISASSEMBLY a Remove piping and hydrostatic unitas necessary to allow repair b Although the unit should have been drained of lubrication be aware that the axle support removal will allow trapped oil to spill NOTE An oil Supply is blocked in the hydrostatic pump when notrunning so upon reassembly hydrostatic charging is notnecessary c Any attempt to service the hydrostatic pump will be done so only upon the authorization of Eaton or the equipment manufacturer Tecumseh does not authorize repair or adjustment of the unit d Clean all exterior surfaces in preparation for disassembly 3 DISASSEMBLY INPUT DRIVEN BEVEL GEAR AXLE SUPPORT a Remove the axle supports If supports are different or if there is a chance for confused reassembly scribe alignment marks 78 2500 SERIES TIMKEN THRUST ee ROLLER BEARING Pa XO i 8 N 2 x b Remove and discard square O ring seal c Ifthe tapered roller bearings are loose remove them d Position the unit on the cover up side then remove the dowels and screws Liftoff the cover and discard the gasket AXLE AND DIFFERENTIAL ASSEMBLY THRUST OR TABBED WASHERS OUTPUT SHAFT AND See HIGH RANGE DRIVEN GEAR LOW RANGE 7 DOS BOLT HEADS HIGH RANGE Low RANGE AWA
16. worn to a diameter less than 750 Replace other parts showing wear looseness cracks etc 3 DISASSEMBLY To disassemble the shifter and fork assembly would be the same procedure as assembly exceptin reverse 4 ASSEMBLY a SHIFTER FORK INDEXING BALL AND SPRING Reassemble the shifting assembly by following the illustrations Lay the parts on the bench On a clean paper or shop cloth Pay particular attention to the annular grooves in the shifter rods and the snap ring NEUTRAL GROOVE INDEXING BALL SHIFTER ROD B SHIFTER FORK NEUTRAL GROOVE 1 Assemble the shifter forks to the shifter rods The shifter forks are inter changeable NEUTRAL GROOVE SNAP RING ANNULAR INDEXING BALL SHIFTER FORK Slide the shifter fork into the shifter rod until it comes to the hole with the indexing ball and spring With a flat blade screw driver press the indexing 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 The arrow from the words NEUTRAL GROOVE is passing through the hole for viewing SHIFTER RODS NEUTRAL POSITION SHIFTER FORKS ANNULAR GROOVE SNAP RING When the shifter forks are properly
17. Bentonite grease 30 ounces total Apply grease to top of shift fan 52 11 To seal the case and cover at the end of the shifter brake shaft a flat plug is placed there end opposite the brake assembly Clean the mating surfaces of case and cover place a continuous thin bead of sealantall around the seam Use Loctite Gasket Eliminator 515 Tecumseh partnumber 510334 or the Loctite SN RTV 598 Tecumseh part number an menu Install the cover screws and torque to 90 100 inch pounds Replace index 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 APPLY LUBRIPLATE EE ee oe Fe a 12 Priorto installing the brake assembly apply a lightfilm of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Install brake assembly BRAKE BRACKET Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkages may vary Consult equipment owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wea
18. JULIE AR AAU 101 AT TI I SPACER REMOVEBEARING COLLAR MUST FACE BEVEL SPUR GEAR COUNTERSHAFT BEVEL SPUR GEAR AND SPROCKET SHOULDER With collar on countershaft sprocket facing the bevel spur gear install sprocket onto serration and install chain Install all 4 thrustwashers MUST be positioned on the shifting gear of the output shaft i SUNT AA Install bronze bearings and disc and sprocket Install shaft assemblies into case utilizing piloting locators on bearings to properly align notches in case CAUTION Be sure bearing locators are seated in transmission case TORQUE SCREWS 70 90 IN LBS SHIFTER PLATES 2 Install shifter assembly 12 oz Bentonite grease around gearing and reinstall cover on case Torque cap screws 90 110 in Ibs To puttension on the index ball spring and setscrew Tighten down to flush then two 2 turns in below flush Check for binding by turning input shaft Install transmission on equipment Install brake and linkage and adjust to disengage when clutch is engaged Consult equipment Owner s Manual APPLY LUBRIPLATE T ee i es gr A BRAKE BRACKET Lily STi Apply a light film of lubriplate to the inside of lever portion which contacts pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Brake and linkages may vary NOT
19. RightAngle Drive These units consist of input Shafts output shafts and the beveled gearing necessary to change the direction of power transmission atright angles By positioning the drive bevel gear on the input shaft nearest the input end opposite rotation will be attained from that of switching the beveled gear around to the side away from the input end of the shaft Casing and bearings are identical A cover identifies each unit as being either a left hand LH ora righthand RH right angle drive b 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 c Shafts Couplings Pulleys etc These items are part of the total transmission unit and are used to connect angle drives and other attachments The serrated couplings match the serrations on the shafts of the angle drives or on connecting shafts TERMS USED AXLE The shaft which connects the wheel or hub to the differential unitand transmits force back to the wheels Sometimes axle refers to the differential and axle combination as in the term TRANSAXLE 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 itis often the best means of distinguishing the series in question BEARING BLOCK Strip Use
20. See Section 2 Lubrication Chart These are examples of directions of drive units LEFT HAND 92 LEFT HAND RIGHT HAND RIGHT HAND RIGHT ANGLE DRIVE MOVEMENTS C SMOOTH COVER RIGHT ANGLE DRIVES SERVICE E A Leaking lubricant Correct lubricant leakage by replacing the seals at the input and output shaft as described above 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 below flush Use tool 670293 to protect the seal when replacing the cover and seal assembly over the input shaft Place the seal sleeves on the shaft and coat with oil Slide the sealed retainer over the sleeve Tighten the seal retainer screws and remove the sleeve SHEET METAL E OUTPUT SHAFT SCREW H SEAL HOLE IN SEAL 2 Output shaft seal replacement Remove the seal by punching two small holes in the seal with an awl as close to the outer edge of the sealas possible and opposite each other Use care when making holes in seal so that ball bearing underneath is notdamaged Do notuse a drill Insertsheet 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 sleeve 670293 on the shaft lubricate generously with oil and slide on the seal Drive the seal into the
21. and housing to the transaxle housing check the shifting forks for neutral position Always use new gaskets between the shift lever housing and the transaxle C SHIFTING ASSEMBLY 1 GENERAL a SHIFTER FORK INDEXING BALL AND SPRING 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 INDEXING BALL SHIFTER ROD B SHIFTER FORK NEUTRAL GROOVE 3 Stop 3 Speed Transaxle Shifter Rod amp Fork Assy SHIFTER FORK INDEXING BALL AND SPRING b NEUTRAL GROOVE INDEXING BALL AND SPRING SHIFTER ROD B SHIFTER FORK NEUTRAL GROOVE 4 Stop 4 Speed Transaxle Shifter Rod amp Fork Assy Shifting assemblies are removed from and in stalled into transaxles by squeezing the top end of the shifter rods This causes a binding that retains all parts during removal or installation 2 INSPECTION a b Replace the shifter stop if worn or damaged Examine the teeth and 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 in the gears will create cocking and difficult shifting Replace the gear if this condition is present Replace the shifter shaft needle bearing if wear is evident See the Chapter on bearings for removal Replace if the bearing surface of this shaft should be scuffed pitted or
22. as a lubrication seal 5 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 output pinion 1 in needle bearing cap O rings on countershaft are larger than those on brake shaft ends Always replace with new Seals whenever removed FLANGED SQUARE CUT FLANGED BUSHING O RING BUSHING SHIFTER BRAKE p SHAFT y AN LRI a AN j NS a SHIFT ey je A N e G K cys nt nitty is WS 0 CS ATK et KY Ni lt SQUARE CUT COUNTERSHAFT O RING SPROCKET COLLAR 6 Angle the shifter orake shaft and countershaft chain sprocket ends toward each other Note the collar on the sprockets face the bevel gear Remove chain SPUR GEARS SPLINE FOR CHAIN SPROCKET GEAR 1 Moe Tus MLL HOI A TTY Ci N Ly LL iii fi Ma SPROCKET THRUST WASHER EEEN FLANGED BUSHING 7 Remove the sprocket bevel gear spur gears thrust washer and flanged bushing The spur gears are splined to the countershaft FLANGED BUSHING SPLINE FOR SPROCKET DISC BRAKE FLANGED HIFTER BRAKE GHC SQUARE CUT O SQUARE CUT o NOTCH RING THRUST WASHER WASHER SHIFTER GEARS 8 Remove the square cut seals 2 and flanged bushings 2 thrust washers 2 on shaft ends Spur gear spacer sprocket shift collar with keys thrust washers and shifter gears 29 OLD STYLE NEW S
23. assembled to the shifter rods and positioned in neutral the ends of the notches in the shifter forks are in alignment 101 tan menu CHAPTER 11 BEARING AND BUSHING SERVICE C NEEDLE BEARING SERVICE It is advisable to use an arbor press to remove and in stall needle bearings A GENERAL BEARING AND BUSHING CARE 1 Bearings bushings and bearing surfaces should 3 be thoroughly cleaned prior to examination Examine closely for scuffing wear pitting and abnormal conditions Replace if any conditions mentioned appear Use a good grade of clean solvent to clean bearings After cleaning always use clean lintfree cloth to dry and wipe bearings Immediately coatcleaned bearing with lubricant to prevent rusting or corrosion If the bearing is to be stored wrap in oil proof paper until needed Ball bearings will be damaged if spun with compressed air Moisture from compressed air will cause rust Take care of bearings in the case and cover Cover them to keep out any foreign matter Place gasket surface down on clean paper and cover with clean cloth Never clean the lubricant from new bearings This lubricant prevents damage before the transaxle lubricant enters the bearing B BALL BEARING SERVICE The ball bearings used in the outer ends of the axle supports are sealed Without removing but with the axle out rotate the inner race with the fingers If any roughness is noted replace the ball bearing assembl
24. be caused by the brake not releasing To determine absolute neutral the hole in the tapered control shaft must face straight up and down at this point make sure the OEM linkage is in neutral To properly fasten the control lever to the shaft torque the nut to 25 35 ft lbs 34 48 3 NM of torque 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 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 notreleased from the brake disk Adjust the brake linkage to release the brake completely when the foot pedal is released Hard to shift Typically hard to shift symptoms are not caused by the hydrostatic unit The shift arm Should move with relative ease Approximately 40 50 inch Ibs 4 48 5 6 NM atthe transaxle for foot pedal units or 150 200 inch lbs 16 8 22 4 NM for hand operated units This varies depending on the type of linkage 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
25. case BEARING BLOCK DIFFERENTIAL ASSEMBLY When assembling this unit make sure all parts are there first because the unitis put together in your hands and placed in the case at the same time Axles and gears must be on center line of ring gear Bearing block in case must have flange to the lefthand side Block in cover must have flange to the right hand side 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 40 Bentonite grease around bearings gearing and top of shift fan then reinstall cover on case Torque cap screws 90 100 inch pounds tan menu 14 Clean the mating surfaces of case and cover 15 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 Partnumber 788093 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 install Check for binding by turning input shaft APPLY LUBRIPLATE ama A BRAKE BRACKET 16 Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and br
26. hard shifting condition is caused by the shifter clutch linkage or an internal problem in transaxle or transmission On level ground start the engine and allow the engine to run Using the OEM supplied linkage de clutch the foot operated clutch and shift the gear shifter or on units equipped with a hand operated gear clutch shift lever shift the transaxle or transmission If shifting is difficult try shifting the unit with the engine shut off If the unit 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 Check the clutch shifter and brake linkage for the proper adjustment Use the guidelines provided by the OEM to check for the correct linkage positioning 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 Damaged shift keys gears or shifter brake shaft Belt guides missing or improperly adjusted to close or to far away See equipment manufacturer specs A a a NOTE DO NOT REMOVE TRANSAXLE UNTIL YOU HAVE CHECK ITEMS 1 AND 2 Ifthe cause is internal remove the unit from the tractor disassemble and determine the cause of the failure tan menu CAUSE REMEDY UNIT CANNOT BE SHIFTED OR DIFFICULT TO SHIFT Gears improperly installed Review positioning of gearing Forks and Rod assembly incorrectly installed Remo
27. is a lightweight unit usually used in riding mower or similar application The 600 series has a vertical input shaft at the top of the case The case is aluminum contributing to a considerable weight saving Variations in the series which determines the specific model number such as 603 603A 609 etc includes 1 Shiftlever 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 B 800 Series This unit has 3 to 6 speeds forward and 1 reverse The bearings are oil impregnated bushings with needle bearings or ball bearings on axles input and output shaft C 820 Series This unitis a heavy duty unit with 2 to 6 speeds forward and 1 reverse which can be used with ground engagement attachments Sleeved needle bearings are used in place of oil impregnated bushings on all shaft ends and ball bearings are Standard on axles D 900 Series The unitis like the 800 series transaxle except that the 900 can be 2 3 or 4 speeds forward and 1 reverse E 910 Series This transaxle will offer a forward and reverse unit The speed will change with the use of a vari drive pulley arrangement F 915 Series This unit has 3 to 5 speeds forward and 1 reverse This unithas a gear driven reverse
28. may fall off the shafts upon removal NOTE BENTONITE GREASE MAY STAIN CLOTHES CARE SHOULD BE USED WHEN HANDLING BEARING STRAP DIFFERENTIAL BULL GEAR SON SP uN A Se 5 AXLE BEVEL REON EI GEAR 6 fr OPK s N SX N R amp Ji A er CA Cc iC NN SS 5 Remove the bearing strap on the bull gear of the differential Some models do not use a bearing strap 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 53 OUTPUT SHAFT ASSEMBLY lt a COUNTERSHAFT ASSEMBLY Q Sy O 9 SHIFTER BRAKE SHAFT ASSEMBLY 6 There are 3 shaftassemblies 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 7 As these assemblies are taken apart lay the parts out in a systematic order This will help to make reassembly easier and inspection of all parts possible Clean each part of grease as the parts are laid out To remove keys from the shifter orake shaft you must first remove the large snap ring from the snap ring groove Be careful not to stretch or twist snap ring it is notnecessary to remove Snap ring from shaft NEEDLE BEARIN
29. 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 Italso acts as a Spacer between shafts and the case and cover TRANSMISSION A system of varying sized gears ina case some of which can be slid along a shaft to vary gear ratio in the gear train The net effect is to change speeds to the rear wheel according to the type of work being done UNIT See PEERLESS UNIT GENERAL SERVICING PROCEDURES Introduction The following service procedures should be understood and practiced whenever service must be performed on a Peerless unit Before removal of unit from equipment look for a Loose drive belts b Improperly adjusted or badly worn clutch c Loose orlostsetscrews and or sheared keys in drive and driven pulleys Oil saturated drive belts and clutches Bad operating habits such as clutch riding Oil leaks If found refer to paragraph F Any trouble which might be pointed up by operating the unitand equipment IF POSSIBLE Review Service Bulletin 304 gt amoa Removal of the Peerless unit from the equipment a Jack up equipment so that transaxle is accessible Use wood blocks to prevent equipment movement Do not use bricks cement or cinder blocks b Visually inspect Peerless unit for oil leaks cracked housing binding or rubbing of parts or o
30. orake 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 Place a shifting washer onto the shifter orake shaft with the rounded edge towards the shifting keys Continue this procedure until all the gears on both shafts have been added ten menu NOTE Itis not only important that gears match up diameter wise but must match up according to thickness As all the gears are placed back into the assembly each should be packed with Bentonite grease BEARING ASSEMBLY THRUST WASHERS SLEEVE NEEDLE BEARING O RING ASSEMBLY THRUST SPACER BEARING WASHER 6 Inthe model pictured a thrust washer thrust bearing thrust washer and sleeved needle bearing with O ring are placed on the countershaftnextto the reverse sprocket P lace a spacer washer and sleeved needle bearing with O ring next to largest spur gear The sleeved needle bearing installation will have the step facing outward and the wider portion of the bearing sleeve to
31. reverse gear and thrust washer On the output side of the shifter orake shaft remove the bronze bushing thrust washer and output spur gear ae 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 orake shaft and slide the shift keys and shift collar off the shifter brake shaft REVERSE FOR B INPUT 8 To disassemble the counter spur gear shaft remove the bushing thrust washer and spur gears or spacers if used the last spur gear is held in place by a retaining ring Remove the retaining ring and slide the spur gear and forward drive bevel gear off the splined end of the shaft The bushing thrust washer and reverse drive bevel gear can be removed from the unsplined end of the shaft NOTE A Whena B inputis used the input bevel gears will be in opposite of picture The drive spline on this Shaft also moves SPACER a BSS SSS Ba SS es SS SS ES SSS SS SS ES Ea Sg BS ES H SS M THRUST WASHERS ILLUSTRATION 1 9 To disassemble the output shaft remove the bushing thrust washer large output spur gear Spacer small output spur gear thrust washer and bushing Illustration 1 NEEDLE BEARING FLUSH WITH HOUSING OIL SEAL 5 oD 150 THRU
32. shift fan prior to removal of the gear shaft assemblies from the case It will be difficult to keep parts from falling off the assemblies note position of parts before removal Remove bearing cap differential shiftfan output shaft assembly and then both the shifter brake Shaft and countershaft simultaneously o 1O RING OUTPUT GEAR ee BEARING E z PINION THRUST BEARING SLEEVE WASHER WASHER OUTPUT PINION AND SHAFT Remove sleeved needle bearings Remove large thrustwashers and large outputgear The output pinion gear is machined directly onto the output Shaft in most models There is at least one model in which the output shaft is splined to accepta splined output pinion gear and a splined output gear 33 34 SHIFTER BRAKE SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY 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 lt SNAP RING BEARING INPUT SHAFT e NEEDLE BEARING amp _ SEAL THRUST WASHER Large O RING y THRUST WASHER Small THRUST BEARING CB gt THRust WASHER GREASE THESE CUPPED THRUST AREAS WASHER INPUT PINION SNAP RING INPUT SHAFT The input shaft can also be removed and inspected or serviced Remove the snap ring on the bevel gear and pull
33. the differential This axle goes up to the side of the bull gear where the center shaft slipped in Center the bevel gear on the other axle to 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 If damaged or old replace them NOTE Some models will have an offset input in those units the differential assembly begins with the shortest axle SHIFTING RUBBER SEAL Install the shifting fan with the pin in the groove of the shifting collar Grease top of shift fan Fill the unit with 18 oz of Bentonite grease Install top bearing block with flange to the right 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 partnumber 788093 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 R einstall the ball spring and set screw on the models thathave them The setting for the screw is flush to the cover Check for binding by turning input shaft 43 APPLY LUBRIPLATE ame fl g BRAKE ST BRACKET Zi 13 Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which con
34. the case and cover bearing Surfaces For bearing maintenance refer to COLLAR Chapter 11 Examine all parts after removing oil with cleaning solvent Check for any wear and replace any damaged parts D REASSEMBLY 1 Press new bearings onto output shaft 2 Install the two large oil seals for output shaft in the case and cover first 3 The collar has to be removed next Place a jaw type puller around the collar and pull off This will expose 3 steel balls equally spaced in holes around output shaft There will be a Snap ring in the inside of the collar After the collar is pulled off discard snap ring 20 WASHER _ IDLER SHAFT 3 Place idler gear into case with washers on both Sides along with output shaft at the same time 4 Place one input shaft washer on bearing boss next to idler gear Place proper seal protector for input shaft in seal and insertshaftand second washer OUTPUT SHAFT 5 Before closing case and cover together inspect to make sure all parts are present Now place new gasket between case and cover 6 NOTE Make sure oil deflector Is in place before case cover is put together 7 Putcase and cover together and before installing bolts push dowel pins in place so that both halves line up 8 Tighten and torque bolts to 15 to 18 ft Ibs SNAP RING 10 11 12 13 Install 3 steel balls in holes with a little grease to hold them in place P lace larg
35. this unit is described in the Chapter on shifting assemblies If it is evident that the shifter assembly needs no further teardown place it aside in a clean place intact for easy reassembly 10 Remove the low gear and shaft and splined Spur gear Separate gear and shaft Note that NO thrust washer is between the gear and case FOUR HEX BOLTS HEADS UP LOW GEAR SHAFT BEARING OUTPUT GEAR AND SHAFT SPACER 2 GEAR CLUSTER DIFFERENTIAL ASSEMBLY BRAKE SHAFT 11 Remove the two gear cluster and spacer from the brake shaft 12 Liftthe differential unit out of the cover Service information appears in the Chapter on differentials 1 16 THICK 15 16 1 D THRUST WASHER DIFFERENTIAL AND AXLE ASSEMBLY REMOVED 13 Remove the output shaft and gear and thrust washer from each end of the shaft OUTPUT GEAR AND SHAFT 70 1 32 THICK 1 1 D THRUST WASHER IDLER GEAR IDLER GEAR CHAMFERED SIDE UP AWAY FROM BEARING 14 Remove the brake shaft Note that 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 CARRIER LOW GEAR SHAFT BEARING BRAKE SHAFT BEARING 1 32 THICK OUTPUT SHAFT BEARING INPUTSHAFTAND GEAR YA duct ever opENING FLAT SIDE OF GEAR UP SHIFTER ROD SOCKETS QUTPUT SHAFT BEARING SHIFTER SHAFT BEARING SHIFTER ROD SOCKETS OAD 4 ANL YS E ARA S ll AA
36. together in the case and cover Also remove the flat washers off the axle ends Some models will have a slightly different ring gear and use a Single bearing strap in place of bearing blocks 2 DIFFERENTIAL ASSEMBLY BEVEL PINIONS RING GEAR When assembling this unit make sure all parts are there first because the unitis put together in your hands and placed in the case at the Same time 3 MST SERIES DIFFERENTIAL This unit is similiar to the 900 accept it uses no bearing blocks The differential is supported by the shoulders on the ring gear tan menu D DIFFERENTIAL USED IN PEERLESS CAST IRON CASING UNITS RING GEAR HEX HEAD BOLT BEARING SURFACE NOTE The models covered are the 820 1200 1300 1700 2000 2300 and 2400 series 1 The differential construction may vary from the illustrations but is basically similar FOUR RETAINING BOLTS SNAP RING RETAINER I ERNS E AD DEE ISS p lt PINION GEAR CARRIER WITH Riera for rennet THREADED eta BOLT HOLES DRIVE BLOCK DIFFERENTIAL GEAR DRIVE PIN 2 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 case cover t
37. 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 4 SHIFTING WASHER 5 COUNTERSHAFT LARGE INPUT BEVEL GEAR Saar WASHER Insert the countershaft into the smaller reverse Sprocket Then install the large bevel gear with the bevel facing away from the reverse sprocket Place thin thrust washer on the countershaft next to the bevel gear NOTE Depending on model the bevel may be in stalled 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 WASHERS ja oS SPUR GEARS ae CUT OUT SIDE FLAT SIDE 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
38. 2 Install new oil seal using seal sleeve No 670293 and driver until seal is flush with housing POSITION OIL SEAL Tl USE THE PROPER THEN USE SEAL SIZE SEAL DRIVER TO SEAT PROTECTOR SEAL SQUARELY TO THE PROPER DEPTH 13 Position input bevel gear in mesh with output Shaft bevel gear Tap the input shaft into place with a soft hammer Use one hand to hold the gear and shaft to dampen tapping blows Be Sure gear is on the marked side of the housing 14 Align shaft and insert ball bearing on each bearing surface by hand 15 Install new seals in retainer caps using driver 16 Using seal sleeve 670293 over the shaftserrated ends install new gaskets and bearing cap Tighten retaining capscrews to 8 11 ft Ibs 17 Lubrication See Section 2 Lubrication Chart 18 Install gasket and cover and secure with self tapping screws Torque to 20 24 in Ibs 19 Align scribe marks and install T Drive on equipment 95 1100 SERIES A GENERAL 3 Todisassemble the input cage assembly first remove the nutand washer that holds the large yii Sass keyed gear onto the shaft With an outside puller a if necessary remove gear Roller bearings will be attached k MAEKA Eaves P aN WA The 1100 series angle drive is a heavy duty gear box used with larger equipment with a larger H P rating up to 20 H P This unit is of cast iron 4 Remove bearing from gear by using a bearing constr
39. 2 are located on the spur gear shaft one on each end 45 BULL GEAR AXLE BEVEL lay ly 0 J f b A S Ls ETT I AA J A AW Ut FY kes Ms Aj lags lt pe Ny ita lpr Ci i 8 As these assemblies are taken apart lay the 6 Remove the bearing strap on the bull gear of ArT parts out in a systematic order This will help 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 to make reassembly easier and inspection of all parts possible Clean grease from each part as the parts are laid out To remove keys from the shifter orake output shaft you must remove from case the large snap ring from its groove Be careful not to stretch or twist snap ring it is not necessary to remove snap ring from shaft NEEDLE BEARING FLUSH WITH HOUSING ly A PAN ee S N i SQUARE CUT O RING 46 OUTPUT SHAFT ASSEMBLY REVERSE IDLER ASSEMBLY COUNTERSHAFT ASSEMBLY 7 There are 2 shaftassemblies in this transaxle the countershaft and the shifter orake output Shaft assembly Remove these assemblies as complete as possible from the case NOTE Dependent on the rotation of the countershaft gears
40. 6 To install seals use a 1 Seal protector Position seals so that itis 100 below flush LUBRICATION After assembly fill with 1 pt E P 90 gear oil mein menu CHAPTER 10 SHIFTING ASSEMBLY KEY SPRING HEIGHT To check shifting keys for loss of spring height place the short flat portion of key on flat surface as shown measure the distance from surface to key tip The measurement should be from 400 to 460 if measurement is below 400 key should be replaced A SHIFT PATTERNS VERTICAL INPUT FRONT OF EQUIPMENT 700 SERIES 800 820 SERIES 900 910 915 920 930 SERIES 600 SERIES MST SERIES AVAILABLE IN 2 to 8 SPEEDS FIGURE SHOWS 6 SPEED UNIT HORIZONTAL INPUT FRONT OF EQUIPMENT LEFT HAND INPUT RIGHT HAND INPUT 1700 SERIES 1 1200 SERIES 1700 SERIES 2000 SERIES 2000 SERIES NO LEFT HAND INPUT 1200 SERIES 2300 SERIES 2300 SERIES 99 B SHIFT LEVER ASSEMBLY 1 GENERAL a 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 itfrom the transaxle Clean around the lever housing to prevent dirt from falling into the transaxle Cover this opening if possible 2 DISASSEMBLY a QUAD RING SEAL Place the shift lever in a vise so that the shift lever housing is atleast one inch from the top of
41. AP RINGS 2 etl SHIFTER ROD c 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 FORK NORMAL lt POSITION Y HIGH RANGE a D GROOVE Te J N EY wee h S l i i N Sg D XN LOW RANGE SNAP RINGS NEUTRAL GROOVE SHARP SIDE OUT d Shifter Mechanism 1 Check spring for tension and ball for wear 2 Check shifter rod grooves for wear Be sure Snap ring sharp edge goes away from shifter fork 3 Inspect shifter fork for straightness and wear 79 ein or e Differential 5 ASSEMBLY Install parts reversing the disassembly procedure watching out for the following SETSCREW FORK SPRING A It sce Zi 7 oe ee Ty BALL SPRING AND SETSCREW a After shifter rod is positioned install ball then Spring and setscrew Turn setscrew in slowly while raising and lowering rod until ball stops rod movement b Be sure that thrust washers and spacers are between every shaft and case and cover c Threads of differential bolts must be coated with standard stud Loctite The bolt heads on differential are up when installed 1 Check security of parts d Install new gasket It may be helpful to dampen 2 Check snap rings for condi
42. E If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out 19 ein menu f SECTION 3 2800 SERIES TRANSMISSION A GENERAL 4 Using a punch remove dowel pins that align case amp cover together 5 Remove the cap screws that maintain the cover to case Remove cover OUTPUT 6 Remove gasketand discard Inspectgears and bearing surfaces HOLES SHIELD MOUNTING 7 Remove the inputshaftand two washers The The Model 2800 series transmission is the first of input shaft and gear are one piece its kind produced by Peerless It s known as a P T O Power Take Off unit This unit mounts on the back side of the Model 2600 series transaxle Some O E M s are using this unit to run auxiliary attachments such as large tillers mower decks or any attachments that need power to make them operate B DISASSEMBLY 1 Clean outside surface of transmission OUTPUT SHAFT 2 To remove small outer snap ring located on the output shaft use a small ice pick or similar 8 Remove output shaft Output shaft bearings tool can be removed by using a bearing splitter and puller WASHER _ IDLER SHAFT 9 Remove the idler shaft and two washers C INSPECTION AND REPAIR 1 Inspect both
43. EST THRUST WASHER SHOULDER COLLAR DISASSEMBLY OF UNIT 1 Remove gear and shaft assemblies from case half of the transmission by lifting the two shafts out of the bearing supports taking care not to disturb drive chain relationship with hubs on Sprockets BEVEL SPUR GEAR COUNTERSHAFT 2 Remove bevel spur gear combination and spur gears from the countershaft these gears are Splined to the countershaft CHAIN SPROCKET SHIFT SPUR GEARS BUSHING OUTPUT AND BRAKE SHAFT OUTPUT SPROCKET 3 Remove the output sprocket and brake disc from the output shaft Remove the bushings shift sour gears chain sprocket collar and keys ASSEMBLY OF 700 SERIES SNAP RING O RING THRUST WASHER SNAP RING Input shaft removal for 700 series in line transmission 4 Remove snap ring from input shaft remove bevel gear and pull shaft through case 5 Inputshaftneedle bearings should be installed flush to 005 below bearing bore surfaces from inside and outside case D INSPECTION AND REPAIR Examine all parts after removing grease with cleaning solvent Replace damaged parts IN LINE TRANSMISSION 1 Install and secure the input shaft and bevel gear in the case See Paragraphs 4 amp 5 under Disassembly Instructions and reverse the order COLLAR OUTPUT AND BRAKE SHAFT 2 Install collar and keys on output shaft Thick Side of collar MUST face shoulder on shaft NOTE A
44. FT BEVEL GEAR b Remove the output shaft bearing by using a large machine bolt washer and nut c The input shaft bearing input shaft and bevel gear may now be driven out of the housing Use tool 670220 Press bearing into housing to remove OUTPUT SHAFT SNAP RING AND BEARING INPUT SHAFT d The top ball bearing in the blind end of the housing is removed by either heating the housing on a hot plate or tapping the housing on the outside with a mallet 91 MOWER BLADE APPLY SMALL AMOUNT OF GREASE BETWEEN NUT AND MOUNTING SURFACE e Rightangle units 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 out put shaft is pulled out the bearing will also be removed INSPECTION Clean all parts in cleaning solvent Examine for wear or damage and replace as needed Use care when handling ball bearings See Chapter 11 Bushing and Bearing Service REASSEMBLY Assemble in reverse of the disassembly instructions Itis important that only ball bearings with snap rings be used for the input shaft and top output shaft bearing Use tool for driving in bearings In the event bearing bore Is tight in housing heat housing on a hot plate Place a steel plate on the hot plate and rest housing on steel plate DO NOT OVERHEAT Work rapidly after removing housing from hot plate Use care to prevent burns LUBRICATION
45. G B IDENTIFICATION This unithas an aluminum tag showing the model number make sure tag is not misplaced during disassembly C STEPS TO TAKE BEFORE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position 3 Ifinstalled O0 E M option remove the neutral Start switch 4 Remove the O ring from the shift rod D DISASSEMBLY INDEX BALL AND PRING LOCATION SHIFTER BRAKE OUTPUT SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFT ROD OPTIONAL SHIFT ASSEMBLY ROD LOCATION 1 Remove the hex head screws that hold the cover to the case 2 Push down on the shift lever rod while pulling cover off of the case 3 Remove the index ball and spring from the shift rod assembly Rotate shift rod assembly upward to remove from shift collar 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 brake assembly 5 Remove the grease from the unit as the parts are removed NOTE BENTONITE GREASE MAY STAIN CLOTHES CARE SHOULD BE USED WHEN HANDLING 940 SERIES The 940 Series is identical to the 915 Series with the exception of 3 added bronze bushings These bushings are located on the shifter brake shaft 1 opposite the brake rotor end The other
46. G FLUSH WITH HOUSING SQUARE CUT O RING SSI L135 eee 150 THRUST WASHER BEVEL GEAR RETAINING RING 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 NOTE Needle bearings are lubricated with E P grease DO NOT USE BENTONITE on needle bearings F or maximum gear train life use only Bentonite grease on all shafts and gears Tecumseh part number 788067B 54 mein menu Tool part No 670251 is used for removal and installation of needle bearings for the inputshaft The needle bearing on the inboard side is installed 135 150 below flush E 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 KEYS 2 OR 4 SNAP RING 2 Grease all keyways and slide keys and collar onto the shifter obrake shaft There are both 2 and 4 key models Place large snap ring back into the snap ring groove On models which have a inner diameter recess cut into one side of the shift collar the recess side must face towards the gears and snap ring for proper gear selection REVERSE CHAIN AND SPROCKETS SHIFT WASHER 3 To assemble this transaxle the countershaft and the shifter orake shaft should be assembled at t
47. IVE GEAR HYDROSTATIC DRIVE MOUNTING SURFACE ee a DRIVEN INPUT GEAR gt HIGH RANGE TRANSMISSION v DRIVE GEAR SPACER V2 THRUST BEARING y A SPACER OR SHOULDER ay N et VN C Ps INPUT SHAFT KS AN THRUST WASHER w T JX TABBED THRUST waste ll MELY 2 sll Bo agpee a SHIFTER AND BRAKE SHAFT P3 i a yam i OIL SEAL e BEVELED SIDES OF GEARS t LI DE a AA OUTPUT SHAFT 4 w T ee FEN O O O E ee j TABBED ee aa ue 5 i WASHER WASHER THRUST WASHER i THRUST SS WASHER SEAL ALS aS SP Saini O RING SEAL i ENT lt S TURNITAN NTA i K BALL BEARINGS 2 L77 ENEE ee Vs ROLLER BEARINGS 2 DAN gt T A LAN NOTE NO BEARING AT THESE POINTS EEA 81 tan menu f SECTION 3 2600 SERIES REDUCTION GEAR AND DIFFERENTIAL UNIT 1 GENERAL The 2600 series has infinite forward and reverse speeds Itis powered by a Sundstrand unit Power to the hydrostatis an engine up to 20 H P rating The 2600 series are shipped without lubrication from 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 SAE Type A automatic transmission fluid 2 PREPARATION FOR DISASSEMBLY a Remove pipi
48. NERAL The differential assemblies of all Peerless units utilizing them 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 oe en aware of differences in each unit therefore less A apt to allow these differences to cause mistakes HOUSING in assembly een PINION GEARS B MODEL 100 DIFFERENTIAL 1 DISASSEMBLY d Remove snap ring bevel gear and thrust washer Slide axle from differential carrier a Clean outside of differential Remove all housing keys pins etc Remove all burrs from l hardened shafts differential carrier housing To replace bushing use bushing tool 670204 2 ASSEMBLY a Slip axle in differential housing carrier Place thrust washer and bevel gear on axle and secure with snap ring Make sure flat side of snap ring is away from gear b Place pinion gears and thrust washers on drive pin and insert assembly into either differential housing carrier c Use 3 oz Bentonite grease as lubricant d Assemble differential carrier housings and LOCK NUTS 4 Sprocket with 4 bolts and locknuts NOTE No oil seals or gaskets are required in this unit A few units use a g
49. NTIFICATION 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 See Illustration B 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 A REMOVE FILL PLUG 7 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 See Illustration C 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 See Illustration C DETENT SCREW BALL SPRING D 6 Remove the set screw spring and index ball See Illustration D 57 D 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 CAUTION With the new sealant between the case and cover it may be necessary to pry them apart If you find this necessary ONLY PRY INTHE MOUNTING FOOT AREA See Illustration A page 57 A 2 With a rubber or leather mallet tap down on the shift lever rod while removing the cover from the case If rust has occurred on the shaft remove it with emery cloth b
50. O E M Mechanic s Manual for type of lubricant tt To be filled through shift lever opening 16 0z 473 ml Oil 2300 6402 1892 ml Oil SECTION 3 IDENTIFICATION RIGHT ANGLE DRIVES 1100 SERIES 100 SERIES 700 SERIES 900 SERIES 920 SERIES 930 SERIES 810 SERIES 801 SERIES 915 SERIES MST and VST SAMPLE OLD STYLE SAMPLE NEW STYLE O MOD 506 O MST205 1 I Specification Number PEERLESS ILILILILIL Manufacturers Requested Features 1 275 1374 SERIAL 6 0 0 2 Lo Individual Serial Number _ Manufactured on the 275th Day Serial Number J ulian Date Manufactured in 1991 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 ein menu f SECTION 4 TORQUE CHART TORQUE VALUE MODELS 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 2 17 7 Bolt 1 4 20 Case to Cover 600 Series 84 108 Bolt 5 16 18 Axle Support Housing 600 Series 156 180 Bolt 1 4 20 Shift Lever Housing 600 Series 84 108 Bolt 1 4 20 Brake Disc 600 Series 84 108 Bolt 1 4 20 Case to Cover 800 amp 900 Series Except 820 Bolt 1 4 20 Brake Disc 800 900 amp MST Series Bolt 5 16 18 Case to Cover 820 Serie
51. OR REVERSE FROM ANY FORWARD TO REVERSE GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to the many variations of equipment braking systems adjustment and repair to the components and linkages are not considered warranty OPTIONAL INPUT SHAFT INPUT SHIFT ROD LOCATION INDEX BALL SPRING AND IDENTIFICATION qh j NEUTRAL START BRAKE BRACKET SWITCH SCREWS BRAKE LOCATION CAN BE ON RIGHT OPTIONAL OR ON LEFT SIDE A GENERAL The 820 series is similar to the 920 series transaxle in basic operation It has up to 6 speeds forward and 1 reverse The 820 Series is a heavy duty unit which is suited for ground engaging attachments B IDENTIFICATION This unit contains an aluminum tag showing the model number C PRE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position 3 Remove set screw spring and index ball 4 If installed O E M option remove neutral start Switch D DISASSEMBLY 1 Remove hex screws that hold cover to case 2 Push the shift lever rod in while pulling cover off of the case Shifting assembly may temporarily re main in case Remove cover 3 Remove two brake bracket screws and remove brake assembly BEARING THRUS SHIFTER BRAKE SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY Uy f EG SLEEVED NEEDLE BEARINGS DIFFERENTIAL NOTE Remove grease from the unitas parts are removed Remove the
52. 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 788067B COLLAR DISC BRAKE SHOULDER cp ine SHIFTER BRAKE SHAFT Grease the keyways and slide keys and collar on output and brakeshaft Thick side of collar MUST face shoulder on shaft Service replacement shifter brake shafts will come with 4 keyways in the shaft instead of 2 NOTE When repairing the unit used the same number of keys removed Do not increase or decrease THRUST WASHER SEPARATES GEAR FROM BEARING CUT OUT FLAT SIDE OF SIDE OF GEAR MUST GEAR MUST FACE FACE SHOULDER OUTBOARD ON SHAFT END OF SHAFT Install the thrust washers and shifting gears onto the shifter orake shaft The number of gears and or spacer will be determined by the number of speeds in the transmission WASHERS A running change has been made to the shifting 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 shifting 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 shifting keys The washers are interchangeable SHIFTING GEARS The 2 sides of the shifting gears are different One side is flat an
53. R SHAFT AND THRUST WASHERS g Remove the input shaft and gear assembly Note that thrust washers are on both ends of shaft h Remove output pinion and gear splined to it Note position of thrust washers on each end of pinion i 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 2 INSPECTION AND REPAIR a Clean all parts and examine for wear or damage b Referto the Chapter on differentials for service when working on differentials Refer to the Chapter on bushing and bearing service to replace any loose or worn bearings d c Remove and discard oil seals from input and brake shafts Check axle seals and replace if e any evidence of leaking exists If protective seal sleeves were notused when removing seals and retainer assemblies replace seals Replace seals after assembly Use seal sleeves and correct drivers See Chapter 1 Paragraph F f QIL LEAKS SEAL AND GASKET SERVICE for service d Clean the case and cover Protect bearings from dirt Lubricate bearings to prevent rusting g 3 ASSEMBLY a Install thrust washer in cover for input output and brake shafts h b Install brake shaft into gear in cover c Install input and output shaft with gear and position spacers on brake shaft Install thrust washers on all shafts COVER THRUST WASHER i INPUT SEAL BRAKE THRUST
54. SNAP RING RETAINER SHIFTER STOP a SHIFTER p RODS KEE SHIFTER FORKS IN NEUTRAL POSITION BRAKE SHAFT SHIFTER STOP SHIFTER 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 notches in the shifter forks should be aligned with notches in the shifter stop This indicates that shifting assembly is in a neutral position The shifter stop must be so positioned so that the notch aligns with notches in shifter forks For service of the shifting assembly refer to Chapter 10 INPUT SHAFT SNAP RING RETAINER SEAL BALL BEARING BEARING 13 Transaxle Assembly a Install new seal thrust washers and bearing on input shaft Note sequence and install into case using seal protector THRUST BEARING b 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 CAUTION Make sure that bearing and thrust washers remain in place while assembling idler gear shifter and brake shaft c Insertthe washer and then the three gear cluster assembly Making sure that the bevels on the two shifting gears are facing
55. ST WASHER BEVEL GEAR RETAINING RING ILLUSTRATION 2 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 Illustration 2 11 Tool part number 670251 is used for removal of needle bearings for the input shaft 12 After clean up ofall parts a complete inspection should be done Check for chipping or damage to teeth keys or the 4 key slots in the shifter gears You also should inspect the 2 keyways in the shifter shaft for damage chipping or knicking Worn or damaged parts must be replaced mein menu f E REASSEMBLY The tool part number 670251 can also be used for installation of the needle bearings for the input shaft The needle bearing on the inboard side is installed 135 150 below flush The top bearing is installed flush to the casting 1 Usean EP bearing grease and apply it to the bearings in the cover Place the seal into the cover with the grooved side of 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 cuto ring thrust washer and input bevel gear on the shaft on the inboard side and secure them by placing a snap ring in Snap ring
56. T OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD 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 A GENERAL 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 ofthe option of input shaft and gear positioning on either side of the bevel gear the axle output will vary The model described in this section is a five speed forward single reverse The input shaft for the model described in this section is located to the left of the bevel gear INPUT SHAFT f Oily ir aal77 le Tiree IDENTIFICATION TAG B IDENTIFICATION The unit contains an aluminum tag atlocation A or B showing the model number 28 C PRE DISASSEMBLY l Zi ALLENHEAD Clean outside surface of transaxle Position shift lever in neutral position as indicated by the shift pattern Remove Allen head screw washer s and the shift lever If installed O E M Option remove neutral start Switch Remove setscrew spring and index ball NEUTRAL DISC BRAKE START SWITCH LEFT OR OPTIONAL
57. TECUMSEH fe ee Oe we en Oe rn en HANDBOOK This manual covers all Peerless Gear models as follows Right Angle and T Drives P 91 100 600 601 700 800 801 820 900 910 915 920 930 940 1000 1100 1200 1300 1800 2300 2400 2500 2600 2800 MST VST TECUMSEH PEERLESS MOTION DRIVE SYSTEM TRANSMISSIONS TR DIFFERENTIALS RIGI TECUMSEH TABLE OF CONTENTS Page CHAPTER 1 GENERAL INFORMATION SECTION 1 Model Overview and Terms Used cccccccseeceeceeeeeeeeeeeeeseeeessaeeeeeseaeeeeeas 1 6 SECTION 2 Lubrication Requirements cccccccceeseececeeeeeceescueeeeeeseeeaseceeseaaeeessseaeeeeesaaaes 7 Se IONS TEASING AMOINS seisseen E E E 8 SECTION 4 Torque Specifications ccccccccccessecceeceeeeceeeeeeeeeeeeeeeeeeeesseeeeeeseseaeeeeesaaeeeeseaas 9 SECTION 5 Trouble Shooting Table ccccccccccccecesseeeeeeeeeeeeeeseeeeeeeeeseeeeeeeseaeaeeeeeeas 10 12 CHAPTER 2 TRANSMISSIONS AON T FOO OOS in AA tren iteeniiAtanade 13 16 SEC ION Z 700R SONOS sanaccoireconnecenecasebeteed E T T A 17 19 SECTION 3 2000 GENES neinar EEA EEE O i TaS EEE 20 21 CHAPTER 3 TRANSAXLES SEC HON eo 0 8s 6 oe nnn ne ee ee 22 26 SECTION 2 601 Slow Speed SOMOS isrssrriusoninie in ae a EA uaeetassiewees 27 SEO TION 3 B00 SOF SONES seru E a aa 28 32 SECTION A B20 CS S erne TEE 33 36 SECTION 5 900 Se eS siiin aaee E E a 37 40 SECHNON G OTO GONOS simien aE EE O 41 44 SEC
58. TION 7 915 Series 940 Series saieiccnescessanmatessudntensonseousenivasciudaimeasciuteteiacdietienncent 45 48 SECTHON 8 20 SS voters ears neuen toch eats atna tact avin ener senlecenteananeaeaanemonenaeteinaeuaaancat 49 52 SEC HON J O30 SSCS weaetrtitaetesuneiastsvetnntanitnieeesandanletiuaidenncelapaueiammucaaeenneetetn 53 56 SECHON 10 MST200 CCS vay chert ron EEA 57 62 SECHON 11 YST205 DOTES aiacisjancuai da tatadolabnassuriacstiuecteceatamaenancensidniatiegieasnisesietocds 63 64 CHAPTER 4 3 SPEED TRANSAXLES SEC HON TITZ EO an E E E EEE EE 65 67 CHAPTER 5 FOUR SPEED TRANSAXLES SECHON T 2300 GEOG sorarsa ena e E N E 68 73 CHAPTER 6 REDUCTION GEAR and DIFFERENTIAL UNIT SECHON T TIO ONO Taa E T TEE 74 75 CHAPTER 7 REDUCTION GEAR and DIFFERENTIAL UNITS SECHON T A00 o gt oo ea a E E 76 77 LOIN 2 OO SCS arrrareetateteoceee er nats EN E E 78 81 DEC TION 3 2600 SOUS Sa cesccecictesancaecntnbvesuntveusnecivtandcvaccemedenntalsruninneddtnosuensstlbedatauaicuevenanes 82 84 CHAPTER 8 DIFFERENTIALS wsictsccstetscsctetssecesssssscccsesscsasssnccessncsnssnsecenonsseeonsanecnsssnensnnns 85 90 CHAPTER 9 eS cionsiocair O 91 95 TOO SOS a O E E 96 98 CHAPTER 10 SHIFTING ASSEMBLY ccccesseeccceseeeccenseeecesseeeenaseeeeanseeseenseesonans 99 101 CHAPTER 11 BEARING and BUSHING SERVICE s sssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnne 102 103 NOTE The VST Series is not addressed in this issue with th
59. TYLE SEALED BALL BEARING 9 Remove differential from case Remove seals 2 needle bearings or ball bearings 2 flanged bushings 2 and thrust washer Teardown and reassembly procedures for this unit may be found in the Chapter on differentials FLANGED BUSHING EUIR ay ey Ee a cs FLANGED WASHER DIFFERENTIAL BUSHING The 800 Series has used 4 styles of bearings on the axles The earliest style A was a smaller loose cage needle bearing and must have the seal to the outside of that bearing Style B must have the seal to the outside of the bearing When bearing style C is used a square cut O ring must be used on each side of the bearing Bearing style D is a sealed ball bearing used in H D application Styles B C and D are interchangeable All needle bearings must be repacked with grease Do not use Bentonite grease in bearings NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT O RING SSS L135 sad oU THRUST RETAINING RING WASHER BEVEL GEAR 10 Remove retaining ring on bevel gear side from the input shaft remove bevel gear and pull shaft through case The square cut O ring must be replaced if removed Tool PartNo 670251 Is used for removal and installation of needle bearings for the input shaft The needle bearing on inboard side is installed 135 150 below flush 30 ein menu f E REASSEMBLY L Apply E
60. The differential or axle unit is connected through a chain drive a 700 Series This unit can be 3 4 or 5 speeds forward and 1 reverse The brake system can be mounted on either side of the unit b 700 H Series This unitis built with almost all interchangeable parts with in it s two cases except that this will be a H shift pattern This unithas 3 or 4 speeds forward and 1 reverse c 2800 Series This unit is built to work on the 2600 series Itis used as a P T O transmission to run external equipment 4 DIFFERENTIALS The only self contained differential axle unit built by Peerless is the 100 series Itfeatures hardened axle shafts of various length and machined for various methods of hub attachment The case Is cast 6 tan menu aluminum and the differential gears are sintered metal or cut steel The differential pin is held in place by the four retaining capscrews Oil Lite bushings reduce friction during differential operation The drive sprocket is part of the unit which depending upon application can be in any 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 lefthand rotation so that they can be used in various combinations for synchronous operation a
61. UARE CUT O RING 6 With the shifter orake shaft and countershaft ends angled together install the chain on the Sprockets SQUARE THICKER LARGE WASHER OAT AREA ITH GREASE PINION 135 BOTH 150 ENDS 7 Forcorrect positioning of the needle bearings use removal and installation Tool Part No 670252 Fillthe area between the needle bearings with grease before installing on the countershaft 31 FLANGED BUSHING THRUST WASHER V NOTCH SQUARE CUT iy SHIFTER GEARS SHIFTER BRAKE SHAFT FLANGED BUSHING SPUR GEAR OUTPUT SQUARE CUT SEAL PINION IN EACH END OF FLANGED BUSHING Install the output and pinion gears the flat washer square cutrings needle bearing closed end and spacer on one end and thrustwasher and flanged bushing on the other end Note thatthe V notch on the bushing fits into recess Vin case A square cut Seal fits in each recessed end of output pinion Also one square cut ring fits into recessed end of needle bearings closed end SHIFTER BRAKE SHAFT BUSHING DIFFERENTIAL FLANGED BUSHING 32 OIL SEAL 10 11 BEARING COU NTER RETAINER SHAFT ASSEMBLY DIFFERENTIAL ASSEMBLY Install the flanged bushings 2 flat washer needle bearings or ball bearings 2 and oil seals 2 with seal grooves facing out For teardown and reassembly of the differential see the Chapter on differentials Install differential in case Install s
62. Use Loctite Gasket Eliminator 515 Tecumseh part number 510334 or the Loctite Silicone RTV 598 Tecumseh partnumber 788093 Guide cover over shift rod and position onto case Install the cover cap screws and torque 90 100 inch pounds Install the neutral start sensing switch if applicable Replace O ring on shift rod Check for binding by turning input shaft APPLY LUBRIPLATE BRAKE BRACKET Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkages may vary Consult equipment owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out SECTION 8 920 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to the many variations of equipment braking systems adjustment and repair to the com
63. WASHER q I CAS li OUTPUT im mtr NE NOTE POSITION OF CAPSCREW HEADS E OUTPUT SHAFT BRAKE SHAFT SPACER Install differential unit with cap screw facing down Position new gasket on slightly raised dowels and install case Turn down eightsocket head cap screws lightly Tap dowel pins in and tighten cap screws to 10 ft Ibs Use seal sleeve and install seal and retainer assemblies Position new O ring on seal retainer Be sure the mounting pad is in correct position Install each axle supportand bolt down Torque the cap screws to 13 ft Ibs Use the proper seal sleeve and driver replace inputand brake shaft seals Rotate shafts to check for binding or noise Add lubricant 2 pints S A E EP 90 oil to level of fill plug with unitin normal mounted position THRUST WASHER SPLINED COUPLING SEAL NOTE POSITION OF AXLE SEALED SUPPORT BALL BEARING NOTE EQUAL LENGTH AXLE EXTENSION FROM EACH SUPPORT SECTION 2 B 2500 SERIES REDUCTION GEAR AND DIFFERENTIAL UNIT 1 GENERAL Most 2500 Series two speed gear boxes are run by an Eaton Model 10 hydrostatic unit Power for the hydrostat is supplied by as presently approved an engine 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 from Peerless Original equipment manufacturers fill each gear case with lubricant
64. Y FROM SHIFT ROD SNAP RING FORK DRIVEN DRIVEN DRIVEN DRIVEN LARGE GEAR e To remove the inside components remove in the following order 1 Remove the differential and thrustwashers BALL SPRING AND SETSCREW BRAKESHAFT RETAINING RING 2 To remove the shifter rod and fork the set screw spring and ball should be removed at the outside of the case INPUT THRUSTWASHERS INPUT HIGH RANGE SHAFT SPACER BEVEL TRANSMISSION Shown l GEAR GEAR Assembled BEVELED ROUNDED ff THRUST OR THRUST ff TABBED BEARING SPACER Gear WASHER 3 Remove both the input and shifter gear and Shaft assemblies along with the shifter rod and fork 4 Remove the inputshaft and gear assembly 5 Remove the output shaft and gear 4 INSPECTION AND REPAIR a Axle Supports 1 Check ball bearings and bearing races for wear rustand ease of rotation Clean interior of the support if necessary 2 Replace oil seals in axle supports 3 Check for cracks ein menu f b Case and Cover 1 Check for leaks or cracks 2 As necessary replace needle bearings as described in Chapter 8 3 Do notreplace brake shaftand shifter rod seals until the unitis reassembled BEVELED SIDE OF GEAR TEETH BEVELED SIDE OF HIGH RANGE GEAR TEETH LOW RANGE SHIFTER AND THRUST SPACER BRAKE SHAFT Z Aea A iS ne OUPTPUT THRUST OR PINION TABBED LOW RANGE GROOVE HIGH RANGE GROOVE SN
65. ake disc must be free of grease and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkage may vary Consult equipment owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out SECTION 6 910 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FORWARD OR REVERSE FROM FORWARD TO REVERSE GEAR NOTE Due to the many variations of equipment braking systems adjustment and repair to the components and linkages are not considered warranty A GENERAL The 910 series is available in 1 speed forward and 1l reverse INPUT SHAFT COVER CASE SHIFT ROD HEX SCREWS B IDENTIFICATION This unit contains an aluminum tag showing the model number C STEPS TO TAKE BEFORE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position 3 Ifinstalled O0 E M option remove the neutral Start switch 4 Some 910 models will have a detent ball and Spring Remove the set screw spring and ball D DISASSEMBLY
66. all the bushings are in their V notches in the case 99 CENTER SHAFT BEVEL GEAR BEVEL PINION GEARS BULL GEAR NOTE The differential must be assembled out of the case and then placed in the case Apply Bentonite grease to axle contact areas of case 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 to 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 IG o O Isos o o2 OjO O 9002 10 Install the shifter assembly and bearing strap pack the transaxle with the remaining Bentonite grease 30 ounces total Apply grease to top of shift fan 56 11 To seal the case and cover at the end of the shifter brake shaft a flat plug is placed there end opposite the brake assembly Clean the mating surfaces of case and cover place a continuous thin bead of sealantall around the seam Use Loctite Gasket Eliminator 515 Tecumseh part number 510334 or the Loctite Silicone RTV 598 Tecumseh part number 788093 Install cover screws and torque to 90 100 inch pounds tan menu Replace index ball spring and set screw and turn set s
67. ar bevel pinion gears with center shaft and the axles 49 COUNTERSHAFT ASSEMBLY OUTPUT SHAFT ASSEMBLY lo HANA leo CT WL pii o oO OJQ Q 0022 SHIFTER BRAKE SHAFT ASSEMBLY There are 3 shaftassemblies in this transaxle the output shaft the countershaft and the shifter brake shaft assembly Remove these assemblies as complete as possible from the case 7 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 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT ant ee 135 BEVEL GEAR Ww Ro THRUST RETAINING RING WASHER 50 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 shaftis removed Tool part No 670251 is used for removal and installation of needle bearings for the inputshaft The needle bearing on the inboard side is installed 135 150 below flush SHIFTER BRAKE SHAFT ein menu 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 ge
68. ars Tecumseh part number 788067B E REASSEMBLY 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 Grease both keyways and slide keys and collar on shifter brake shaft RGER DIUS ACER WARD IFT KEYS SPROCKET REVERSE CHAIN AND COLLARS SPROCKETS NEUTRAL SPACER 3 To assemble this transaxle the countershaft and the shifter orake shaft should be assembled atthe 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 and install the larger Sprocket onto the shifter orake shaft with the collar away from the shifting keys 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 againstthe shoulder of the shifter brake shaft NOTE Theirhave been a few 900 models built with identical neutral collar halfs These can be installed either direction BEVEL GEAR COUNTERSHAFT 4 Insertthe counters
69. asket between b Remove 4 locknuts bolts and sprocket the two housings Separate differential carrier housings l If no gasket is present seal the housing with Loctite 598 part number 788093 using a 1 8 bead C MODELS 600 800 900 910 915 920 and 930 1 DISASSEMBLY of 600 PINION BEVEL GEAR DRIVE PIN c Remove drive pin pinion gears and thrust washers as a unit a Drive out roll pin that secures drive pin with suitable driver 85 Gi DRIVE PIN THRUST WASHERS Thrust washers must be removed before attempting to remove the pinions Remove bevel pinions simultaneously by rotating the gears in opposite directions gears will move out of position SNAP RING Remove snap ring bevel gear and thrust washer Slide axle out Inspect bushings and gears for wear and replace when necessary 2 REASSEMBLY OF DIFFERENTIAL ASSEMBLY 86 a Place axles leftand right into differential gear assembly Install thrust washers NOTE The axles differ in length so select the proper axle Place bevel gears on the shaftand install snap ring in groove on the shaft CUP FACES OUT mein menu f c Install bevel pinions SIMULTANEOUSLY FROM OPPOSITE SIDES by rotating pinions in opposite directions while sliding into position in gear assembly Check alignment by inserting fingers into drive pin holes If not aligned drive pin cannot be inserted Remove and replace bevel pini
70. ate the units block the assembly to prevent c Drain oil from unit falling then remove the three hydrostatic mounting d Remove seal retainers and O rings screws Lift either unit from the other If any binding occurs remember that the drive shafts are held in e Remove eightsocket head cap screws securing common rotation by a splined coupling and the case to cover Drive dowel pins out of case coupling may have a Slight bind on the driveshafts into cover then lift case off of the cover DIFFERENTIAL UNIT NOTE POSITION OF SS DIFFERENTIAL DRIVE CAPSCREW HEAD Xf PINION AND GEAR REASSEMBLE IN QUTPUT COVER SAME WAY COAT INSIDE OF COLLAR MOUNTING SCREWS 3 WITH E P LITHIUM GREASE DOWEL PIN l DRAIN PLUG ARK SHAFT b Once separated to make any further repair to the a NIN D js N ET hydrostatic unit it must be returned to the brand A AND GEAR unit dealer who sold the vehicle for his service yA gt FILL LEVEL PLUG arrangement DOWELPIN 7 7 o f Before removing differential unit note the c To combine the hydrostatic drive and the 2400 unit position of the cap screw heads Replace the coatthe splined coupling with E P Lithium grease unit in the same way to insure that axle lengths or Install it on the 2400 input driveshaft will be correct when installing axle supports 76 OUTPUT PINION INPUT SHAFT GEAR GEAR AND AND THRUST THRUST 77 KA WASHERS WASHERS BRAKE SHAFT 4 GEA
71. bevel is inward towards the keys On models with a B 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 out put gear followed by a bronze bushing and rubber Oring Then place a washer on the opposite end of shaft to complete the assembly of the shifter orake output shaft REVERSE GEAR COLLAR ot a LOCATION FOR SPACER SOME MODELS The countershaft musthave 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 some five speeds a spacer will be placed next to the largest spur gear on all other models leave a space the width of the large bevel gear and then assemble the remainder of the spur gears with the reverse Spur gear assembled with the collar side inward The small washer is placed next to the reverse Spur gear to complete the counter shaft assembly 47 The two assembled shafts can now be placed in to the transaxle case If model has the reverse idler held in place by the case insert reverse i
72. burrs and dirt from shafts On hardened Shafts use a stone to remove burrs 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 22 INPUT SHAFT SHIFT LEVER HOUSING BRAKE SHAFT 2 After removing axle housings place the unit in a receptacle bench or clamp the transaxle in a soft jaw vise Position the transaxle so that the socket head cap screws are facing up DOWEL PIN 3 Remove the socket head cap screws holding the case and cover together Drive out the dowel pins used for alignment of the case and cover SEAL PROTECTOR SHIFTER GEARS SHAFT DIFFERENTIAL TEZE CENTER ASSEMBLY a is kre atti i CLUSTER 7 Remove complete shifter assembly by grasping shifting gears shaftand both shifter rods as a unit 4 Use a seal protector on axle shaft and lift off transaxle cover assembly Because this seal NOTE Examine assembly carefully if no is a single lip type it may be reused if care is service is required retain assembly as a unit taken to see thatitisn t cutor scratched Discard for easy reassembly If service is necessary gasket refer to the Chapter on shifting assemblies GRIDS es ama y B E DIFFERENTIAL FASTENERS Mi E S Sr oes B TEA F i i cA uE CA pur SHAFT 8 Remove reverse idler shaft spacer and gear 5 To remove differentia
73. c Brake pads and brake disc must be free of grease and oil NOTE To secure brake lever hold bottom nut and torque top nutto 100 in Ibs 600 SERIES BEARING TOOLS PART LOCATION TOOL REMOVE amp REPLACE Brake Shaft 670210 Axle 670204 Input Shaft 670207A Center P late 670205 Brake Shaft 670213 BEARING SIZER 27 needles 30 needles Differential 670204 Cluster Gear 670204 Idler Gear 670210 Axle Housing 670204 Reverse Idler Bearing must be flush with top of case Secure with Loctite SECTION 2 601 SLOW SPEED SERIES GENERAL A The outside appearance is exactly the same as the 600 Standard The following is just the difference between the two series Everything else is exactly the same IDLER GEAR i gawo fry 4 EC ZO 7 Aste An EA Fo K Rey LI A 1 Underneath the idler gear is one 1 washer in stead of a thrust bearing and two 2 thrust washers 2 The idler gear is different than the standard SNAP RING THRUST WASHER BEARING ie 7 A 5 Z Z Z A A Il THRUST WASHER 3 The inputshafthas one 1 thrust washer only instead of a thrust bearing and two 2 thrust washers 4 The inputshaftand bevel gear are also different than on the standard 600 transaxle Everything else is the same 27 mein menu f SECTION 3 800 801 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRS
74. ce and crush ring out of cap and discard C INSPECTION Clean all parts in cleaning solvent Examine for wear or damage and replace as needed W hen roller bearings are removed with puller Discard do not reuse Also discard races ein menu f D REASSEMBLY Its very important when assembling this unit that all new seals and O rings be used l Replace snap rings on the output shaft Press keyed gear on if necessary 2 3 When pressing roller bearings into place with press make sure inner bearing race is used NOTE Service bearings in this unit may have a shim in the box along with a new outer race When pressing the bearing next to the gear place shim if present for that bearing and race next to the gear first then the bearing Install the other bearing that fits into the cap without shim Discard the shim NOTE There may be shims in the service bearing kit Only the bearings nextto the gears may need a shim only if the shim is in the kit 4 The race thatis used with roller bearing on the gear side mounts into the case Press carefully until seated NOTE Make sure that all races and roller bearings are kept together as provided in the kit 97 CRUSH RING 5 Before installing the cover install new crush ring into cover first Place new race up to ring To properly set up the output shaft preload place shaft into box place cover ove
75. ce to either prevent entrance of foreign matter or prevent leakage of lubricant OUTPUT OR OUTPUT SHAFT On a transaxle the shaft that contains the output pinion which Is in direct mesh with and drives the differential Ina transmission the exposed shaft which 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 bolts in Peerless units except the 2400 series The output gear assembles into transaxle cover PEERLESS UNIT OR UNITS The complete Peerless assembly which is part of the EQUIPMENT The Peerless unitis that assembly being described REDUCTION GEAR AND DIFFERENTIAL UNIT A Peerless unitthat reduces a high RPM input speed to a suitable axle speed without the use of a transmission Since there is a single gear train there is a Single inputspeed to output speed ratio however axle speeds are infinite depending upon input speed 3 REVERSE IDLER 915 Series Gear between reverse gear of countershaft and reverse gear of shifter orake shaft that allows unit to operate in Opposite direction REVERSE IDLER A gear added to the gear train SO when In mesh reverses the direction of all gears driven after it Its number of teeth also affects the reverse gear ratio The center gear of the three gear cluster always is in mesh with the REVERSE IDLER and the large s
76. crew one 1 turn below flush Install the neutral start sensing switch if applicable Check for binding by turning input shaft APPLY LUBRIPLATE BRAKE BRACKET I 12 Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkages may vary Consult equipment owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out F 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
77. d cover to case 2 Push shift lever rod in while pulling cover off of case Shifting assembly may temporarily remain in case Remove cover 3 Remove two brake bracketscrews and remove brake assembly SHIFT FORK FAN ASSY NOTE Remove grease from the unitas parts are removed Prior to removal of gear shaft assemblies from the case the shifter fan may be removed It will be difficult to keep parts from falling off the assemblies Note position of parts before removal i g WA WD a DNA O DN O W ER m 4 Remove gear and shaftassemblies from case half NOTE Before disassembly observe how V notches on the flange bushings fit into recess V of case 37 COUNTERSHAFT 6 BUSHING TUM T PONANA TEE O T T TAI AT WET FEE HA TTT A To disassemble countershaft output pinion and Shaft assembly simply pull apart COUNTERSHAFT COUNTERSHAFT Remove the two 2 thrust washers sprocket bevel gear spur gears and flanged bushing The sprocket bevel gear and spur gears are splined to the countershaft OUTPUT GEAR PINION GEAR WASHER 38 a WASHER 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 SHIFTER GEAR 8 9 SHIFTER NEUTRAL COLLAR SPACER SHIFTER SHAFT Remove the square cut O ring 1 and fla
78. d the other side is cut out The flat side of the gear is placed onto the shaft towards the shoulder of the shaft or towards the shifting keys FLANGED BUSHING SPROCKET SHIFTER BRAKE SPLINE FOR DISC BRAKE SQUARE CUT O FLANGED BUSHING SQUARE CUT 0 RING THRUST WASHER IK JH NO VE NOTCH SHIFT NOTCH CHAMFER COLLAR SHIFTWASHER SHIFTER GEARS 4 NOTE The thrustwasheron the shiftgear end of the shifter and brake shaft does nothave a chamfer on the inside diameter Install sprocket Spacer Spur gear and thrust washer on output shaft Be sure collar on sprocket faces the shift collar Install bushings on both ends of shifter brake shaft install square cut O rings on end of flanged bushings NOTE Depending on model the bevel gear may be installed one of two ways For description purposes in this section the model used has the wide angle of the bevel gear facing the left SPUR GEARS SPLINE FOR CHAIN SPROCKET GEAR a Or e a a iit alt fo v SPROCKET THRUST WASHER eal FLANGED BUSHING 5 Install bevel gear and smallest to largest spur gears thrust washer and bushing to the counter Shaft Install the sprocket FLANGED SQUARE CUT FLANGED BUSHING O RING BUSHING SHIFTER BRAKE SHAFT SPROCKET COLLAR Nw rx A V SA AS SHIFT N Ca a WASHER YA AAA N 4 6 i EES cow KOD AN i COUNTERSHAFT SPROCKET COLLAR SQ
79. d tighten the eight socket head capscrews Torque screws to 10 ft Ibs Unit can now be placed flat on the work bench Place seal retainers and new Seals in position CAUTION Sleeves must be used to protect seals especially axle ends or where wheels attach OIL SEAL SLEEVE USE DURING ASSEMBLY AXLE OIL SEAL BRAKE SHAFT OIL SEAL RETAINER O RING THRUST BEARING ASSEMBLY 15 Install new O rings on seal retainers and position axle Supports to case and cover Be sure mounting pads face in the same direction as when removed Install capscrews and torque to 13 ft Ibs INTERNAL QUAD RING SEAL USED AT THIS POINT ROLL OR DOWL PIN CAPSCREWS TORQUE oe cia 10 FT LBS GASKET 16 Install shift lever housing and new gasket E TESTING AND LUBRICATION 1 Fortesting referto Chapter 1 Paragraph H 2 For proper lubrication type and amount refer to Chapter 1 Section 2 73 CHAPTER 6 1300 SERIES REDUCTION GEAR AND DIFFERENTIAL UNIT SECTION 1 1300 SERIES A GENERAL ee ae REMOVE MOUNTING The 1300 series unitis driven by a hydrostatic motor SCREWS 4 connected to the unitcase The transmission function is accomplished by the hydrostatic controls The Peerless unit therefore only reduces input shaft Speed to the differential and axle assembly Ct MY 2 X N E ANN lt N 5 IONN 1 To separate the hydrostatic unit from the 1300 supportboth par
80. d to support the ring gear of the differential BEVEL on a gear different from bevel gear Roundness of the meshing sides of gear teeth allow easy shifting Because this is about the only allowance made to make easier shifting the unit Should be stopped before the shift to keep these Spur gears from getting chewed up BEVEL GEAR A gear with teeth ground on a diagonal so that when it meshes with a second bevel gear power is transmitted atan angle If the angle is 90 the gearis known as a MITER GEAR BEVEL PINION The smaller of two meshed bevel gears in a gear train BRAKE or BRAKESHAFT The shaftona Peerless unit Transaxles and Transmission to which a braking system may be attached It is in the gear train with the differential to stop it when the operator brakes Itis usually larger in diameter than the in put shaft due to its function of taking shock loads experienced in braking CASE That part of the unit casing half which contains the shift lever and input shaft openings The other half is the COVER because the reassembly must be done into one or the other depending upon the series CHAMFER Diagonal milling atthe corners of gear teeth to remove sharp edges The usual reason for chamfer is to eliminate the possibility of hardened gears chewing softer metal COUNTERSHAFT Splined shaft which holds gears that are in constant mesh with shift gears and transfer power flow from input to shift
81. dler into the case prior to inserting shafts NOTE Dependent on the rotation of the countershaft gears the reverse idler assembly will be located either above the reverse gears and held in place by bosses in the cover or below the reverse gears and held in place by bosses in the case The reverse idler assembly will always be located against the thrust of the countershaft reverse gear Make sure thatthe 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 to axle contact areas of case 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 itin the case as an assembly Reposition the rubber seals on the ends of the axles in their bosses If damaged or old replace them A J N7 I gt yy Ta a i q we SAN S Sy T AINA SAN Y T SS Install the shifter assembly bearing strap and reverse idler assembly if applicable Pack the transaxle with the remaining Bentonite grease 10 ounces total Replace index spring and ball 9 tan menu Clean the mating surfaces of case and cover place a continuous thin bead of sealant all around the seam
82. e and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkages may vary Consult equipment Owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out SECTION 5 900 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty aar te wie A GENERAL The 900 series is like the 800 series transaxle It has 1 2 3 or 4 speeds forward and 1 reverse COVER CASE HEX SCREWS Pea i B IDENTIFICATION This unit contains an aluminum tag at location A orB showing the model number C PRE DISASSEMBLY 1 Clean outside surface of transaxle 2 Position shift lever in neutral position 3 Remove set screw spring and index ball 4 If installed O E M option remove neutral start Switch COVER CASE LY SCREWS D DISASSEMBLY 1 Remove hex screws that hol
83. e assembly may be disassembled If the axle end has been rolled do not attempt to break the rolled retaining edge The parts are to be replaced as an assembly WASHER DRIVE BLOCK 3 Remove the snap ring and the thrust washer if used Separate the bevel gear and the differential carrier from the axle 2 INSPECTION a SNAP RING See the Chapter on Bushing and Bearing Service Examine gears for wear cracked or chipped teeth Check the internal splines of the gears and axle if the gear is removeable If excess play is noted it may be necessary to replace the individual parts or both the gear and axle Examine drive pinions drive pins and drive blocks for wear and damage Replace excessively worn pinion or the drive pin HOLES THREADED IN ONLY ONE DIFFERENTIAL DIFFERENTIAL CARRIER RING GEAR REMOVED d WASHER Examine the differential carriers One has threaded holes and the other has larger holes so that the bolts will pass through Be sure to order the correct replacement parts Examine the internal bearing diameter of the differential carriers DIFFERENTIAL CARRIER SERRATED AXLE END ROLLER THRUST BEARING WITH ONE THRUST WASHER f 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 3 REASSEMBLY a Oilall parts during reassembly 1 Select the corr
84. e exception of the brake CG Tecumseh Products Company 1996 ein menu CHAPTER 1 SECTION 1 MODEL OVERVIEW AND TERMS USED A TECUMSEH PEERLESS UNITS 1 GENERAL Tecumseh P eerless makes power transmission gear drives for use in all types of lawn and garden equipment IDENTIFICATION OF MODELS Since acquisition by Tecumseh Products Co in 1964 all Peerless assemblies have a model number identification tag or Stamping On units containing axles transaxles or reduction gear and differential units the identification should be visible by viewing the case cover unit from below and behind as itis mounted in the driven equipment If the area is dirt or oil covered however some cleaning may be necessary Write down any numbers found in locations pointed out then compare with the Master P arts Manual Div 8 index For right angle and T drives the identification number is stamped into the housing under the input shaft boss Opposite the cover On transmissions the identification number is stamped on the cover back of the output drive sprocket On the 100 series differential the number is stamped either on cast housing diameter or on the housing end near axle bushing TRANSAXLES A combination of transmission and differential axle are In one compact unit Peerless transaxles are manufactured in many different gear ratio combinations and from 1 to 7 forward Speeds with one reverse A 600 Series The 600 series
85. e when handling ball bearings See the Chapter on Bushing and Bearing Service REASSEMBLY Assemble the unitin reverse of the disassembly When building up the units itis important to install the correct input shaft and identify it with the correct cover if there Is any identification on the cover either R H or L H LUBRICATION See Section 2 Lubrication Chart 94 ein menu f D T DRIVE SERVICE 1 Before removing T Drive from equipment be Sure to scribe marks at one mounting hole to in Sure correct reassembly T DRIVE WITH DIFFERENT INPUT AND OUTPUT ENDS OF INPUT SHAFT DRIVE MODEL T DRIVE WITH IDENTICAL INPUT AND OUTPUT ENDS OF INPUT SHAFT 2 Todisassemble T Drive remove Self tapping screws and housing cover and clean grease from internal area Note and mark near the casting gasket surface on the side where the beveled in put gear is located To switch the T 180 will result in output shaft opposite rotation BEARING CAP AND SEAL RETAINER SHAFT BEVEL IF INPUT END OF SHAFT OTHER ENDIS OUTPUT END INPUT SHAFT BEVEL GEAR 3 Remove capscrews and both retainer cap and seal assemblies Separate and discard oil seals and gaskets BEARINGS ARE SLIP FIT ON BOTH INNER AND OUTER 4 Press inputshaft ball bearings out of the housing with fingers If they stick tap lightly using a drift punch around the outer race HOLD GEAR WITH FINGERS THEN TAP ON END OF
86. ect axle for the side of the differential opposite the hex head bolts If the wrong axle Is used it will require complete teardown of the differential or possibly the entire transaxle if the error is not detected until later 2 Clamp the axle in a soft jaw vise not 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 4 TESTING a Testdifferential action by holding the upper axle vertically and spinning the differential The unitshould 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 E DUO TRAK DIFFERENTIAL 1 OPERATION A cylindrical spring in the center of the unit presses the ten pinion gears against their pockets setting up a resistance to rotation among them This resistance serves to lock up the gears in the differential untila moderate tractive difference in the wheels causes the resistance to be over come 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 aS operation on wet grass or snow The spring acts to transmit torque to the nontractive wheel t
87. ed into shafts 10 TORQUE VALUES TROUBLE SHOOTING l All torque values must be applied The torque value for any fastener will be found in the assembly instruction where that fastener is used All torque specs will be found in Section 4 Overtightening can strip threads compress the gasket excessively and possibly cause binding Cross tightening sequence to half the torque then finally to full torque value Under tightening Oil leakage loosening of attaching parts and possible shifting of the internal parts causing complete failure 5 Since all bolts are readily accessible there is no reason thata torque wrench cannot be used for all bolt and screw tightening 11 TE STING 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 this would be the prerogative of the servicing agency since the following checks are considered adequate 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 of the various shafts inserta tool such as a punch ora socket head screw k
88. een shaftO D and bore of brake disc Brake pads and brake disc must be free of grease and oil Brake and linkages may vary NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out mein menu f SECTION 2 700H SERIES CAUTION TO AVOID PREMATURE TRANSMISSION FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD CAP SCREWS 6 DISC BRAKE SHIFTER ROD The H pattern transmission described here is a 4 speed forward 1 reverse unit TORQUE SCREWS TABS IN 70 90 IN LBS SHIFTER PLATES 2 The 700 series H pattern transmission gear arrangement Is the same as the in line transmission exceptfor the shifting portion and an additional collar on the out putand brake shaftand an additional spacer on the countershaft and spacer on the output and brakeshaft NEUTRAL START DISC BRAKE If installed optional equipment remove neutral start Switch NOTE Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty A DISASSEMBLY OF SHIFTER MECHANISM Clean
89. efore 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 5 There are 3 shaftassemblies in this transaxle The countershaft shifter orake shaft and output Shaft Remove shifter fork assembly and then remove these 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 these assemblies are taken apart lay the parts out in a systematic order This should help to make the reassembly easier CAUTION The keyways can be extremely Sharp use Care in this area 58 SEAL BUSHING SHIFTER WASHERS THRUST WASHER P I N A F 1 i i N h A A i yan i ii Al T B yag EA al ne i HO Ki i yey Y t j i U N ge I SPUR GEAR NOTE INSIDE RECESS FACES KEYS 7 To disassemble the shifter brake shaft start on the spur gear side Remove the oil seal the bronze bushing and thrust washer Remove all of the shifter sour gears or Spacers if used and shift washers Remove the neutral collar
90. er ring into collar and force over output shaft Place smaller ring over output shaft after collar is in place Fill with proper lubricant according to O E M Specs If everything is properly installed unit should Spin freely 21 CHAPTER 3 TRANSAXLES SECTION 1 600 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD A GENERAL There are two 2 types of 600 series transaxles One is the 600 standard series transaxle 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 on the differences of the 601 slow speed transaxle The 600 Series transaxle has an aluminum case and cover The input shaftis on the top of the case Some 600 series transaxles are equipped with optional disc brakes Due to the many variations of equipment braking systems adjustments and repair to these components and linkage are not considered warranty B TRANSAXLE DISASSEMBLY NEUTRAL POSITION 1 Clean the outside surface of the transaxle away from the area where disassembly will take place Position shift lever in neutral position to help disassembly Remove screws 3 holding shift lever Remove all keys from keyways remove all
91. ess side must face towards the gears and snap ring for proper gear selection Place 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 SHIFT GEARS REVERSE SHIFT GEAR NEUTRAL SPACER SHIFTING CUT OUT SIDE FLAT SIDE WASHER NOTE As all the gears are placed back into the assembly each should be packed with Bentonite grease 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 OUTPUT GEAR mein menu Then place a shifting washer onto the shaft with the rounded edge towards the shifting keys Continue this procedure until all the gears and washers have been added in their proper sequence LARGE BEVEL GEAR 00 THIN SHIFTING WASHER The lastshifting washer will be a thin flatwasher 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
92. ey into the keyway however do not force if shaft is binding Reason for unit binding Re used or lack of gasket Oilseal retainers installed backward Mis installed thrust washers Differential installed backwards Mis assembly of shifting parts Mis placement of spacers Foreign matter blocking gear teeth mesh Shifter stop installed backwards Input shaft not completely in case 0 Mis alignment of case and cover Align with dowels before tightening cap screws C OONDPAN mein menu f SECTION 2 LUBRICATION CHART Check the Peerless unit model number before filling with lubricant There may be a difference in the quantity recommended This is dictated by the design of the vehicle and the position of the Peerless unit in it RIGHT ANGLE TRANSAXLES TRANSMISSIONS AND T DRIVES Model Model Model No No Quantity No Quantity 600 24 0z 710 mI Oil 700 12 0z 355 ml Grease __ All Models 700 7 708P MMEA a _ ao pa 900 260z 769mIGrease 1410 P91 43002 3 0z 89 ml Grease 3003 3028 3029 3035 1000 Series 6 oz 180 ml 32 02 946 ml Oil SAE E P 80W900Il 1100 16 02z 473 ml Oil DIFFERENTIALS All Models 30z 89 ml Grease TWO SPEED AXLE All Models 2 0z 59 ml Grease THREE SPEED AXLE All Models 2 0z 59 ml Grease 44 0z 1301 ml Oil NOTICE Grease Bentonite Grease Part Number 788067B Oil SAE E P 80W90 Oil Part Number 730229A t Refer to
93. from case cover kr parting line is 90 neutral Parting Line DIRECTION CONTROL SHAFT DIRECTION CONTROL LEVER POCKET RULE PUSH NUT OIL CHECK SQUARE CUT O RING d EXPANSION BELLOW S CHECK COLD FOR CORRECT DEPTH MODEL and SERIAL NUMBERS HERE Col NY 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 ein menu CHAPTER 4 THREE SPEED TRANSAXLES SECTION 1 1200 CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD A GENERAL 1 The 1200 series transaxles has three forward speeds and one reverse 2 This series is notintended for use with ground engaging equipment That is itshould not be used to pull plows or similar equipment which are pulled through the soil to over turn it Also judicious use is expected in any situation where a severe strain will be placed on the axles AXLE SUPPORT TO CASE COVER ht bh hh ANNI SE poh me EES Ee OAE HOUSING BUSHINGS PRESS FIT 1200 Housing Bushing and Seal Assy On the 1200 series replace the seals after complete reassembly B DISASSEMBLY 1 Positi
94. gears COUPLING A sleeve to connect two serrated Shafts in the same axial plane Used in right angle drive systems or in connecting the hydrostatic drive to the input shaft on 2400 series transaxles COVER That part of the unit casing half which contains the brake shaft opening except the 600 series in which all openings are in the CASE as described in CASE above The case and the cover Switch sides depending upon whether the transaxle is right or left hand drive DIFFERENTIAL GEAR BOLTS Through bolts holding the differential parts together The heads of these bolts must be opposite the output shaft gear except in the 2400 series This is an early check to see that the unit is being assembled correctly DOWEL PIN Alignment pin is used to align the case and cover and other parts in a transmission or transaxle The dowel should be tapped in 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 assembly riding mower tractor etc is built by a manufacturer a part of which is the Peerless unit A check of the equipment ma
95. groove SNAP RING RECESS IN KEY COLLAR SPUR GEAR SPLINE ILLUSTRATION 3 2 Nextassemble 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 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 key Place the notch from the second key on the inside diameter of the 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 Illustration 3 SEAL BUSHIN ene SHIFTER WASHERS yo WASHER a THRUST WA oe Se SNAP RING SPUR GEAR NOTE INSIDE RECESS FACES KEYS ILLUSTRATION 4 3 Place the plain large thrust washer over the key tips on the spur gear side of the shaft nextto the snap ring The sequence thatfollows is reverse gear then the neutral collar and 1st thru the amount of gears the unitis equipped with up to 6 gears largest to smallest Between each gear place a shift washer Bevel facing keys Illustration 4 59 SHIFTING WASHER 60
96. grooving installed Check rod length Replace with correct part Constant mesh gears improperly installed on Reposition gears counter shaft AXLES CANNOT BE TURNED SAME DIRECTION WITH UNIT IN NEUTRAL GEAR Axle housing not installed or not tightened Seal retainers are not properly seated Tighten axle housing bolts Burrs on gearing Remove gear and hone with a stone Parts missing Install missing parts 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 reposition if wrong Bearings not pressed in deep enough Use the proper bearing tool to seat the bearing UNIT DOES NOT DRIVE Differential bevel gears broken Replace 3 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 Replace chain becomes wedged CHAPTER 2 TRANSMISSIONS SECTION 1 TRANSMISSIONS 700 SERIES CAUTION TO AVOID PREMATURE TRANSMISSION FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR FROM REVERSE TO ANY FORWARD GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD A GENERAL The 700 Series in line transmissi
97. haft 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 SHIFTING CUT OUT SIDE FLAT SIDE WASHER 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 orake shaft would be the largest of the shifting gears Place this gear next to the neutral collar with the flat side of the gear next to the collar 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 diameter wise but must match up according to thickness Models with the large bevel gear turned 180 and placed on the opposite side of the reverse sprocket will be explained under assembly variations sub section F 6 pi IE SPACER AWN ST Ci MILLI O RING Place the spacer on the countershaft next to the reverse sprocket Then place a thrustwasher on each end of the countershaft and insert the bronze bushings Place the large washer on the end of
98. he same time Start by placing the reverse chain over the reverse sprockets Make sure that the collars on the sprockets are on the Same side of the chain Install a large washer onto the shifter brake shaft next to the snap ring and then the large sprocket with the collar away from the shifting keys Push the shifting keys through the reverse sprocket and push the neutral spacer over the end of the keys and pull the neutral spacer and reverse sprocket up against the snap ring on the shifter brake Shaft WASHER oe GEAR WASHER SPUR GEAR A COUNTERSHAFT kA V m 4 Insertthe countershaftinto 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 SHIFT WASHERS SHIFTING CUT OUT SIDE FLAT SIDE WASHER 5 Build the gears on the countershaftand shifter brake shaftalternate
99. he shaft O D and bore of the brake disc Brake pads and the brake disc must be free of grease and oil Install the brake assembly ILLUSTRATION 13 10 Refill the transaxle through the fill hole located in the cover This unit requires 16 oz of 80W 90 gear lube part 730229A When completed lubricate the plug lightly on the outside with oil Use a 3 16 wood dowel placed in the recess a and push itinto the plug hole Illustration 13 11 Install the transaxle on the equipment Make any clutch and brake adjustments in accordance with the equipment manufacturers owners manual NOTE If adjusted improperly the unit will exhibit these conditions 1 Will notstop adjusted to loose 2 Continued braking affect or dragging adjusted to tight 3 Hardtoshift Brake applied before clutch releases belt 4 Belt guides missing or misadjusted see Bulletin 304 61 mein on CHECKING OIL LEVEL PROCEDURE Locate tractor on a level surface Depress clutch brake pedal engage parking brake and place deck in lowest cutting position Locate the rubber fill plug next to the shift rod as itenters the transaxle cover ILLUSTRATION 1 4 With a needle nose pliers or needle nose vise grip work under the lip of the plug rocking from side to side until plug is removed Illustration 1 DIPSTICK NO 35942 ONTACT IS FULL PY sy AA 5 f ILLUSTRATION 2 Insert dipstick Part Numbe
100. hifter assembly and pack 30 oz 36 oz 801 Series of Bentonite grease around bearings and gearing then reinstall cover on case Torque cap screws 90 100 inch pounds NOTE On reassembly use either gasket eliminator Loctite 515 part number 510334 or Silicone RTV Loctite 598 part number 788093 INPUT SHAFT IDENTIFICATION TAG 12 Install index ball spring and setscrew in that order into cover and slowly tighten the screw 1 turn below flush If unit contained a neutral Start switch install Check for binding by turning input shaft APPLY LUBRIPLATE T WA BRAKE BRACKET 13 Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkage may vary Consult equipment Owner s manual NOTE If adjusted incorrectly the brake will do one of two things a It will not brake stop the vehicle when the brake is applied or b Ifadjusted too tightly a drag or continued braking effect will be evident until the brake wears out SECTION 4 820 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST
101. hifter gear always shifts into it RIGHT ANGLE DRIVE Interchangeable with HEAD ASSEMBLY The major operating parts are a pair of miter gears A system consists of other right angle or T drive head assemblies and connecting hardware SEAL A mechanism which stops leakage It can be a rubberring as in an O ring or Quad ring a Sealing type ball bearing or mostcommonly a rubber like sealing surface encased in a metal form SEAL RETAINER Found on some models of transaxles and on right angle drives The center of the retainer is bored to the size of the outer diameter of the seal On transaxles the retainer acts to position the differential In the casing on right angle drives itacts as the end cap of the case and is secured with four capscrews SHIFT COLLAR Round collar which retains shift keys onto the shifter obrake shaft The shifter assembly pin or pins slide into the groove on the collar to activate the shift keys SHIFT GEARS Gears on shifter orake shaft that are in constant mesh with spur gears of counter Shaft The shift gear in which the shift keys engage determines the speed of a transaxle SHIFT KEY One of either two or four metal spring steel keys which are held in the keyways of the shifter brake shaft by a shift collar The shift keys are used to Slide through the shift gears and engage the desired gear or speed SHIFT KEYWAY One of either two or four slots in the shifter orake shaf
102. housing until itis flush with the bottom of the housing Use driver DISASSEMBLY 1 Remove the cover gasket and lubricant BEARING AT INNER EDGE OF MACHINED SURFACE BALL BEARING 2 If the unit is built with the bevel gear on the input Shaft toward the cover remove the snap ring on the input shaft from the groove DRIVING BEVEL INPUT SHAFT SNAP RING 3 Remove four screws and the cover and seal assembly esis OUTPUT SHAFT 4 Remove the seal at the output shaft 5 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 out put end ball bearing by driving it out from the inside 93 BEVEL GEAR OUTPUT SHAFT BALL BEARING 6 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 inner ball bearing race INSIDE INPUT BEARING SNAP RING DRIVEN BEVEL GEAR ON OUTPUT SHAFT 7 The ball bearing that supports the inner end of the in put shaft is removed by holding the housing in the hand and tapping the housing sharply on the outside with a soft mallet behind the bearing It may at times be necessary to heat the housing to remove this bearing INSPECTION Clean all parts in cleaning solvent Examine for wear or damage and replace as needed Use car
103. hrust 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 at point A FIZZI FIN 2 2N TU Ss Z TO M ESY 3 The 2000 series three speed and the 2300 series four speed differential Examine the external bearing race on the differential carriers 1 for wear or pitting Replace if evident The differential carriers in this assembly have replaceable bushings 2 Replace if worn in 87 excess of 878 at pointA See the Chapter on Bushing and Bearing Service These differentials have been built with rolled axle ends and also Snap rings 3 as illustrated 1 DISASSEMBLY a FOUR HEX DIFFERENTIAL CARRIER Clean the differential assembly then check and note the axle lengths and their relation to the heads of the four hex screw bolts If the unit will not turn freely note where the unit binds Check and replace those parts RING GEAR BEARING RACE Place the differential in a large vise with softjaws hex head bolts up Do notclamp the vise on the bearing race of a differential carrier 1 Remove the four hex head bolts and the upper axle and differential carrier Remove the drive blocks pinions drive pin and thrust spacer if used by lifting out of the ring gear Tap the ring gear lightly with a mallet to loosen from the differential carrier 88 2 Ifa snap ring is used the axl
104. ifter shafts 3 Inspect shifter fork for straightness and wear e Differential 1 Check security of parts 2 Check thrust washers for wear 3 Check differential lock collar for fork slop Or pin wear 4 Check ball bearings for ease of rotation f Replace any parts if necessary 5 ASSEMBLY Install parts reversing the disassembly procedure watching out for the following a After shifter rod is positioned install ball then Spring and setscrew Turn set screw in Dual Speed until head or screw contacts case b Be sure that thrust washers and spacers are between every shaft and case and cover c Threads of differential bolts must be coated with standard stud Loctite The bolt heads installed are up Refer to the differential Chapter d Install new gasket It may be helpful to dampen the gasket with oil to get it to lie flat 83 o To place axle assemblies into case and or cover grease axle spline ends heavily Push axle through seal use extreme caution when axle splines are going through seal 6 AFTER ASSEMBLY 84 a To install brake shaft oil seal use seal sleeve 670179 and seal driver To install shifter rod oil seal use seal sleeve 670206 and driver 670211 To install locking differential shifter rod oil seal use seal sleeve 670206 and drive 670211 Lubrication for all models is 7 to 8 pints of SAE Type A automatic transmission fluid CHAPTER 8 DIFFERENTIALS A GE
105. igned by Illinois Tool Works The Model 2600 transaxle has the unique customer option of a semi locked differential This system acts like a locked differential until the torque at the axle exceeds 50 70 ft lbs At this point it acts like a regular differential Using the following procedure you can check for proper condition of this optional unit used ona few 2600 models not all units L Liftthe rear of the tractor up so both tires are off the ground Rotate one tire while in neutral the other tire should rotate the same direction If not disassemble the unit If it does proceed to step 2 Lock one axle or wheel assembly so it can not turn Using a torque wrench and socketon 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 If the torque is low you will need to split the ring gear and carrier Remove any shim between the two halves If you do not find a shim you will need to replace the spacer block see Illustration Re assemble and check for proper break away torque as listed above Breakaway should not exceed 70 ft lbs 95 2 NM BELLEVILLE WASHER ORIENTATION mein menu f CHAPTER 9 DRIVES This section relates to service of all Right Angle and T box drives ACCEPT 1100 Series IN NEXT SECTION A GENERAL 1 Priorto removing the assemblies examine the following items that may have failed causing the right angle dr
106. instead of chain driven and the case is sculpted around the gears G 920 Series This series of 900 transaxle offers 3 to 7 speeds forward and 1 reverse H 930 Series This unit has 3 to 7 speeds for ward and 1 reverse The transaxle Is very similar to the 920 series except for the differential and shifter obrake shaft I TheMST Series Manual Shift Transaxle 200 is a sealed unit which uses 16 oz of SOW 90 gear lube part 730229A The MST series is available with up to 6 speeds forward and one reverse Ithas a sculptured case and cover J VST 1800 Series This transaxle incorporates a hydrostatic pump and motor built into the unit The prefix letters stand for Variable Speed Transaxle VST This unit contains two separate oil reservoirs one for the pump and motor containing airless synthetic oil and the other contains EP 90 gear oil for the differential gears This unit sealed for life and not serviceable at this time K 1200 Series The distinguishing feature of the 1200 series transaxles is that the axle Support housings are pressed from the inside of the case and cover therefore are not readily removable until the unit is completely disassembled The casing is castiron for rugged longtime wear L 2300 Series Generally similar to the 1200 series transaxle The distinguishing features are a more massive casing and a larger shift lever opening machined area The obvious difference from the standpoint of app
107. ition Improper shifting is considered abuse because It leads to pre mature wear and failure of the shift keys and drive gears 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 abuse or wear Some Original Equipment Manufacturers OEMs use these transaxles and transmissions in lawn tractors that do not use a foot operated clutch These lawn tractors combine the clutch release mechanism with the hand operated gear shift lever When the gear shift lever is moved through the shift gate from the gear engagement position toward the neutral position the attached clutch linkage moves the idler pulley to release all input drive belt tension from the transaxle input pulley With the drive belt released from the transaxle input pulley de clutched the transaxle is free to turn under a no arrangement include shifting while on an incline shifting the unit while towing any type of load or shifting is considered abuse that results in pre mature shift key and gear wear and failure not a defect in the material or workmanship of the Peerless unit and is not covered under Tecumseh s limited warranty The following illustrations show gear shaft and key damage caused by improper shift and or linkage out of adjustment These examples show evidence of wear or damage that is not considered a defect Use the following procedure to determine if a
108. ives 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 and appear to be damaged right angle drives Shearing devices are also used to absorb a damaging impact load if en countered Replace the clutch members or shearing devices prior to removal of the right angle drive if failure is noted 5 Loose blade retaining nuts Check torque and tighten if required B FINNED COVER RIGHT ANGLE DRIVE 1 Leaking lubricant These drives do not have oil seals or sealed ball bearings If the unit is to be serviced because of lubricant leakage it will be necessary to replace the ball bearings DISASSEMBLY 2 Remove the cover and gasket and remove the lubricant 3 Different output shafts achieve a different rotation by mounting a gear atthe top or bottom of the shaft DRIVEN BEVEL GEAR FINNED COVER DRIVEN BEVEL GEAR IN LOWER POSITION OUTPUT SHAFT a Ifthe driven bevel gear is on the bottom remove the snap ring on the output shaft and pull out the output shaft 1 2 TO 3 4 DIAMETER MACHINE BOLT APPROXIMATELY 4 LONG SHAFT BALL BEARING CN h sa LARGE WASHER TO SS REST ON OUTER BEARING yl METAL PLATE TO PROTECT LOWER i BEARING Nipis INPUT SHA
109. l assembly it may be 9 Remove cluster gear Sub assembly and thrust necessary to replace two or three screws to washer hold center plate assembly down Pull assembly Straight up If tight tap on lower axle with soft mallet CAUTION DO NOT USE STEEL HAMMER Refer to the chapter on differential assembly service Remove gear on top of shifter Shaft CENTER PLATE ASSEMBLY 6 Remove temporary holding screws if used and lift off center plate assembly Discard gasket 23 OLD STYLE LONG MEDIUM LARGE GEAR SMALL SPACER GEAR BEVELED EDGE EDG NEW STYLE 10 Cluster Gear Sub Assembly a The cluster gear can be disassembled All worn gears are replaceable if damaged or worn Preferably use a press to drive the Shaft squarely b The small and middle gear bevel faces down there is no beveled edge on large gear Shorter section between middle and large gear c Key edge ends mustalign with shaft ends THRUST BEARING 11 Remove the idler gear thrust washers and thrust bearing 24 SNAP RING THRUST WASHER BEARING Ie THRUST WASHER 12 Remove input shaft oil seal to allow access to Snap ring Remove snap ring and input 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
110. l chain over two shafts registering chain is placed onto the shaft towards the shoulder on output shaft sprocket and in line with of the shaft or towards the shifting keys serrations on countershaft Be sure collar on sprocket faces shifting keys and collar CHAIN SPROCKET SHIFT SPUR GEARS 7 Install shaftassemblies into case utilizing piloting locators on bearings to properly align notches in case CAUTION Be sure bearing locators are seated in transmission case SHIFTER ASSEMBLY SHIFTER FAN 1 __ BUSHING 2 F BRAKE SHAFT Ban Se SPROCKET zi a s el sxs 4 When correctly assembled the output shaft as Should appear as shown Z 8 Install shifter assembly shaft pins and fan 12 oz Bentonite grease around gearing and reinstall cover on case Torque cap screws 90 110 in Ibs 15 9 For in line transmission install index ball Spring and setscrew in that order into cover and slowly tighten the screw from flush to two turns below flush depending on personal preference 10 Check for binding by turning input shaft Install transmission on equipment Install brake and linkage and adjust to disengage when clutch is engaged Consult equipment Owner s Manual APPLY LUBRIPLATE fe A BRAKE BRACKET ur ii 11 Apply a light film of lubriplate to the inside of lever portion which contacts pins also to outside of lever which contacts flatwasher and betw
111. lication is that these units have four Speeds forward and will be found on equipment that can be used with ground engagement operations NOTE The transaxles described in paragraphs K and L are fairly similar in appearance but do have specific recognizable characteristics Both these units have cast iron bodies for rugged application although the 2300 series is the only unit that can be used in ground engaging equipment applications 3 REDUCTION GEAR AND DIFFERENTIAL UNITS GENERAL These units do not have a transmission function characteristic of transaxles but rather are units to reduce input speed and torque to a Suitable axle Speed and torque The hydrostatic units which match to these units perform the transmission function a 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 characteristic of the 1200 series The hydrostatic unit is of Eaton manufacture and is not serviced by Tecumseh Service Dealers b 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 unit is manufactured by Sundstrand Corp in LaSalle Ill 3 TRANSMISSIONS These units as manufactured by Peerless consist of the shifting mechanism to take a constant input Shaft speed and reduce it to the desired output speed
112. ling the 900 series itis easier to assemble the shifter obrake shaft and the countershaft at the same time REVERSE SPROCKE COLLAR O RING O RING NEUTRAL SPACER Place the reverse chain on the reverse sprockets The collars of the reverse sprockets Should be on the same side of the chain Slide the larger sprocket onto the shifter obrake shaft with the collar away from the shifting keys and Shoulder on the shifter brake shaft 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 ee SPROCKET Insert the splined countershaft into the smaller reverse sprocket Then place the large beveled gear on the countershaft with the beveled side of the gear towards the reverse sprocket If the 900 series is a 1 2 or 3 Speed forward unit place a washer over the shaft and next to the backside of the large bevel gear If the unit is a 4 Speed for ward there will not be a washer in this location Then begin to place the spur gears onto the countershaft alternating with it s mating gear on the shifter brake shaft MUST FACE OUTBOARD CUT OUTSIDE OF GEAR CA SHIFTING GEARS FLAT SIDE OF GEAR MUST FACE SHOULDER ON SHAFT 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 washe
113. ll 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 788067B BEVEL SPUR GEAR COUNTERSHAFT THRUST WASHER SEPARATES GEAR FROM BEARING CUT OUT FLAT SIDE OF SIDE OF GEAR MUST GEAR MUST FACE FACE SHOULDER OUTBOARD 5 Install bevel spur gear and smallest to largest ON SHAFT END OF Spur gears to the splined end of the counter SHAFT Shaft SPUR GEARS 3 Install the thrust washers and shifting gears HUB MUST onto the shifter orake shaft The number of gears FACE BEVEL and or spacers will be determined by the number SPUR GEAR of speeds in the transmission REMOVE N BUSHING WASHERS A running change has been made BEARING to the shifting washers Many models have used AND i the thrust washer with a 45 chamfer on the SPROCKET fs inside diameter The latest style washer has a curved or rounded side The purpose of both washers is to compress the shifting 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 shifting keys The washers are COUNTERSHAFT SPUR GEARS EVEL THICKEST interchangeable SHOULDER mha SHIFTING GEARS The 2 sides ofthe shifting COLLAR WASHER gears are different One side is flat and the T other side is cut out The flat side of the gear 6 Instal
114. ly 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 diameter wise but must match up according to thickness THRUST WASHER SPACER BUSHING THRUST WASHER O RING WASHER 6 Place the spacer on the countershaft next to the reverse sprocket Then place a thrust washer on each end of the countershaft and insert the bronze bushings P lace 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 orake shaft The thin washer and bushing conclude the assembly of these 2 shafts WASHER Mir BUSHING WASHER ate 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 3 shaft assemblies back into the case Make sure that the tabs of
115. mplete unit This has not changed However Tecumseh would like to provide a failure checklistto assistin 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 l 2 3 4 Allow the unit to cool before trying the following steps Put the shift lever in a position that is 1 2 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 l Overheating Heatcan 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 have the
116. nd placed into the case as an assembly Illustration 8 Using seal protector part 670262A place a seal on each shaft with the open side facing in Hold the longest shaft with the bevel gear and washer on itin your hand 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 shortaxle so that itis also centered on the pinion shaft SEAL LOCATION ILLUSTRATION 9 Pick up the entire assembly and place itinto the case positioning the seals in the seal pocket When properly installed the axle shaft should turn freely without any binding Illustration 9 NOTE Before closing up the case make sure the case and cover fit together evenly and all bushings are properly installed With the flat sides of the bushings matching the pockets of the case and cover SEALANT AROUND TWO Se Se BOLTS FROM Soe BOTTOM OF LOCTITE BEAD INCLUDING AROUND SEALS ILLUSTRATION 10 7 To seal the case and cover Clean the mating Surfaces and place a continuous thin bead 1 16 of Loctite 598 Silicone RTV part 788093 around the entire perimeter of the cover to prevent oil from leaking INCLUDING CASE AND COVER SEAL POCKETS Caution must be used when locating this bead so that oil passages that lead to the axle shafts don t become blocked and prevent lubrication in these critical areas Don t forget the two bottom bolts Illustration 10
117. ng and hydrostatic unitas 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 b Although the unitshould have been drained of lubrication be aware thatthe support removal will also remove the axle along with it This will allow trapped oil to spill c 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 of that unit d Clean all exterior surfaces in preparation for disassembly 3 DISASSEMBLY a Remove the axle supports If supports are differentora chance for confused reassembly scribe alignment marks ALIGNMENT SLEVES WILL BE PRESENT BETWEEN AXLE SUPPORT AND UNIT b To remove axle out of support tap lightly with a mallet from inside out A pressed on sealed bearing will be on the end of axle 82 c Position the unitwith cover side up Then remove dowels and screws Lift cover off discard gasket d Toremove the inside components remove them in the following order DIFFERENTIAL 1 There are two different2600 models shown above THRUST BEARING THRUST WASHERS FEO O EDEN COUNTER SHAFT 2 To remove components in the single speed firstremove the differential thrust washers drive gear input shaft countershaft output gear and
118. nged bushings 2 thrust washers 2 on shaft ends shift collar with keys sprocket spacer shifter gears and thrust washers Crh y ys dy hf D WPA amp BEVEL PINIONS RING GEAR 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 NEEDLE BEARING FLUSH WITH HOUSING SQUARE CUT O RING BEVEL GEAR RETAINING RING SST 135 see 150 THRUST WASHER 10 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 Tool part no 670251 is used for removal and installation of needle bearings for the input shaft The needle bearing on inboard side Is installed 135 150 below flush E REASSEMBLY l 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 only Bentonite grease on all shafts and gears Tecumseh part number 788067B Grease both keyways and slide keys and collar on shifter brake shaft When reassemb
119. nual is recommended prior to servicing the Peerless unit tan menu 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 itis located INPUT OR INPUT SHAFT The partofa Peerless unit which is always connected to the drive Its rotational speed is dependent on the driving mechanism All parts of the input system are always in mesh with input shaft and turn whenever itturns 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 in Peerless units the terms can be the same MODEL NUMBER The identifying number of a Peerless unit which will permitselection of the proper parts to repair that unit NEUTRAL SPACER Single or split collar between forward gears and reverse that shift keys engage when unit Is in neutral OIL SEAL DOUBLE LIP An oil seal with two Sealing surfaces to prevent entrance of foreign matter and leakage of lubricant OIL SEAL QUAD RING A Seal with two external and two internal sealing lips Used in the shifter housing OIL SEAL SINGLE LIP An oil seal with one Sealing surfa
120. o move the equipment 2 3 tan menu DISASSEMBLY INSPECTION AND REPAIR Parts breakdown will be found on next page Remove four through bolts Separate axle assemblies from body cores To disassemble axles remove snap ring and retained parts Be sure that flanged thrust washer goes toward hub end of 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 body cores to ring gear so that pockets in one core are out of alignment with pockets in other core Reassemble thrust washers bearing carrier and side gear to axle and secure with the snap ring Install 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 other side to mesh with 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 other axle and secure assembly with four through bolts Torque to 7 10 ft Ibs 89 BODY CORES RING GEAR SPRING ONLY OLDER UNITS SNAP RING DUO TRAK DUO TRAK is the trademark of a patented limited slip differential des
121. on is available in 2 3 4 or 5 speeds forward depending on equipment manufacturer s specifications NEUTRAL START PROVISION OUTPUT a SPROCKET S SHIFT PATTERN 5 OF ROTO SHIFT The two speed unit is not covered here but can be disassembled and reassembled using the same information for the 700 described in this section Optional features include right or lefthand output and disk brake for either in line or H pattern unit NEUTRAL START SWITCH et DISC BRAKE OUTPUT SPROCKET NOTE Due to the many variations of equipment braking systems adjustments and repair to these components and linkages are not considered warranty If installed optional equipment remove neutral start Switch B DISASSEMBLY OF SHIFTER MECHANISM Clean outside surface of transmission Position shift lever in neutral position as indicated by the shift pattern FOR IN LINE SERIES TRANSMISSION SETSCREW SPRING CAP SCREWS 1 Remove setscrew spring and index ball from transmission cover 2 Remove six cap screws that maintain cover to case SHIFTER ASSEMBLY DI mt mT CC ACT OUD f SHIFTER PINS 3 Remove cover Remove shifter assembly includes shafts pins and fan from transmission by lifting shaft out of case 13 REMOVE HUB MUST FACE BEVEL SPUR GEAR COUNTERSHAFT SPUR GEARS BEVEL BUSHING BEARING AND C 14 SPROCKET X BCO I Fa THICK
122. on the shifter forks in neutral 2 When disassembling the unit it should be held so that a It lies on the case properly blocked so that no weight rests on the input shaft or differential yet the case is rigid b Itcan 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 5 6 iP OUTPUT GEAR THRUST WASHER Liftthe cover off from the case Discard gasket Remove output gear and shaft SHIFTING ASSEMBLY Remove the shifting assembly as one unit REVERSE IDLER GEAR SHAFT AND SPACER muh i ia m o a 1 j VPs INPUT SHAFT AND GEAR Remove the reverse idler shaft spacer and gear 65 8 GEAR CLUSTER ASSEMBLY INPUT SHAFT DIFFERENTIAL 66 CHAMFER TOWARD BEARING OUTSIDE END OF INPUT 9 Remove the input shaft 10 Remove the differential NOTE Notice what the relationship of the bolt heads are to the 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 squarel
123. ons as only one tooth out of position will cause misalignment BEVEL GEARS THRUST WASHERS d After aligning insertthrust washers behind each pinion Insert drive pin and secure with roll pin MODEL of 800 DISASSEMBLY Same as disassembly for model 600 except for additional parts on the axle Remove and inspect seals bearings and washers for wear replace if required If differential was disassembled note positioning of differing length axles so correct reassembly may be performed REASSEMBLY Reassemble in reverse order of disassembly CUP FACES BEARING NEEDLE TYPE b Install seal cup end out from the center of differential to prevent dirt entry OS SEAL NEW STYLE EAVY DUTY SEALED BALL BEARING The 800 Series has used 4 styles of bearings on the axles The earliest style A was a smaller loose cage needle bearing and must have the seal to the outside of that bearing Style B must have the seal to the out side 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 H D application Styles B C and D are inter changeable All needle bearings must be repacked with grease C 2 MODEL of 900 910 915 920 and 930 1 DIFFERENTIAL Remove differential from case The differential is one of the first of its kind in that the unit rides and is held
124. outside of transmission Position shift lever in neutral position as indicated by the shift pattern FOR THE H SHIFT PATTERN 700 SERIES TRANSMISSION HEX SCREWS ain SPRING SETSCREW INDEX BALL HEX SCREWS 1 Remove shiftlever by removing four hex screws on shift lever cover 2 With a 3 32 inch Allen wrench remove screw Spring and index ball in three places balls will rollout once spring Is removed 3 Remove six cap screws that maintain cover to case Remove cover B DISASSEMBLY OF UNIT HUB MUST COUNTERSHAFT FACE BEVEL EVEL SPUR GEAR REMOVE BEARING one ta SPROCKET BOT A SPUR GEARS BUSHING THICKEST THRUST COLLAR WASHER 1 Remove gear and shaft assemblies from case half of the transmission by lifting the two shafts out of the bearing supports taking care not to disturb drive chain relationship with sprockets SHOULDER 2 Angle chain and sprocketends 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 chain me BEVEL SPUR GEAR JURA ATVB 101 AT TI I SPACER Disassembly ofthe 700 series H shift pattern includes spacer OUTPUT SPROCKET CHAIN SPROCKET BUSHING SNAP RING OUTPUT AND BRAKE SHAFT BUSHING Disassembly ofthe 700 series H shift pattern includes a second collar and a spacer SNAP MAES BEVEL GEAR THRUST WASHER O RING SNAP RING
125. over should sit rigidly so that the removal of parts can be done ina systematic step by step procedure c Itwillnotfall causing an accident or injury 4 Oil seals are of the double lip type so sleeve protectors do not offer much protection when removing them Upon replacement new seals Should be used INPUT SHAFT BE SURE SEAL 1 32 THRUST WASHER 3 GEAR CLUSTER BRAKE SHAFT HEAD 7 Remove thrust washer and three gear cluster DOWEL PIN CAPSCREWS from brake shaft noting whether the cluster has a sloppy fit a To service the cluster bushings refer to 5 Tap dowel pins into the cover and remove the the Chapter on bearing and bushing service socket head capscrews b Inspectgear teeth for wearing chipping or breaks Wear or chipping on the bevel area only indicates shifting while the equipment INPUT SHAFT ie IS IN motion TURN CW 6 To separate the case from the cover a Liftthe case 1 1 2 to 2 above the cover REVERSE IDLER GEAR AND SHAFT b Tiltthe case so thatthe shiftrods will clear edge l Sa 8 Remove the reverse idler gear spacer and shaft c Rotate the case so thatboss hidden inside from boss in cover Note thatthe spacer goes will clear gears then lift free of the differential between the gear and the cover and that the gear bevels go down Excessive wear on teeth bevels indicates improper shifting technique 69 SHIFTING ASSEMBLY 9 Lift out the shifter assembly Service of
126. ponents and linkages are not considered warranty A GENERAL The 920 series transaxle is very similar to the 900 series The 920 series will be available in 5 6 or 7 speeds forward and 1 speed reverse The 7 speed transaxle will be shown in the teardown portion of this manual COVER CASE HEX SCREWS B IDENTIFICATION This unit contains an aluminum tag at location A orB showing the model number C STEPS TO TAKE BEFORE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position 3 Remove the set screw spring and index ball 4 If installed O E M option remove the neutral Start switch D DISASSEMBLY Iseo 1 Remove the hex head screws that hold the cover to the case 2 Push down on the shift lever rod while pulling cover off of the case The shifting lever may temporarily remain in the case Lift off cover 3 Remove the two brake bracket screws and remove brake assembly 4 Remove the grease from the unitas 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 fall off the shafts upon removal NOTE BENTONITE GREASE MAY STAIN CLOTHES CARE SHOULD BE USED WHEN HANDLING jj G A lt 2 aN ay 9 y J y 5 Remove the top bearing block on the bull gear of the differential Remove the bull ge
127. pped end of the output pinion Place thrust washers on each end and then the large sleeved needle bearings Install the three shaft assemblies into the case BEARING CAP ASSEMBLY 10 BALL BEARING DIFFERENTIAL Insert differential into 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 bolts 90 100 inch pounds Install shift fan and pack transaxle with remaining Bentonite grease 36 oz total Clean mating surfaces of case and cover place a continuous thin bead of sealant all around the seam Use Loctite Gasket Eliminator 515 Tecumseh PartNo 510334 or the Loctite Silicone RTV 598 Tecumseh Part No 788093 11 INDEX SET SCREW SHIFT ROD NEUTRAL START SWITCH Guide cover over shift rod and position onto case Torque cover screws 180 216 inch pounds Replace index ball spring and setscrew and turn set screw one 1 turn below flush Install the neutral start sensing switch if applicable Check for binding by turning input Shaft APPLY LUBRIPLATE ry il re rs 7 BRAKE BRACKET OHIDIN f 12 Prior to installing the brake assembly apply a light film of lubriplate to the inside of lever portion which contact pins also to outside of lever which contacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of greas
128. qual length with grooves which match the fork position to meshed positions of the shifter gears and gears 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 SHIFTER STOP 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 cross to actuate the other fork SPROCKET A geared wheel designed to turn a link chain drive Various numbers of teeth hence Sprocket diameter are available to change output ratios SPUR GEAR A gear having the shaft bore and teeth in a parallel plane T DRIVE A rightangle drive with an input shaft extending thru the case to transmit power axially in a second direction to the right angle output On T drive with dissimilar input and out end of the input shaft care must be taken to insure that the parts do notrun in reverse when reassembled THREE GEAR CLUSTER A 3 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
129. r 35942 Insert the gauge ata 45aangle Check for approximately 1 2 inch of oil when inserted This is 16 ounces of EP90 gear oil Illustration 2 6 7A If oil is needed we recommend using a goose neck 16 ounce mechanics oil can These are readily available at any hardware store Fill the unit with all 16 ounces of the 90 wt gear oil to level indicated Reinstall the plug by lubricating it with WD40 oil or spray lubricant An installation tool can be made by using one of the following procedures ROUNDED END Oi FILL PLUG PUSHER TOOL 3 16 ROD ILLUSTRATION 3 A When the plug Is accessible from the battery box area make an installation tool from 3 16 cold rolled steel rod as shown Illustration 3 LARGE FENDER WASHER STD NO 10 NUT NO 10 SCREW 2 LONG ILLUSTRATION 4 B If working from the bottom or side use a No 10 screw approximately 2 inches 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 re installation of the plug Illustration 4 ein menu SECTION 11 VST TROUBLESHOOTING The information on the following pages has been provided to help understand the internal operation of the VST Do notuse this information to attempt any internal repairs Tecumseh s current policy on hydrostatic transaxles that have internal failures is to replace the co
130. r shaft without case cover shim and O ring Tighten and torque the 4 bolts to 200 in Ibs at 50 inch pound increments 6 Remove cover and place new case cover shim in place with new O ring and torque to 200 in los at 50 inch pound increments SOFT PLUG 7 To reinstall 1 3 4 soft plug tap in carefully with lip up until 1 16 below flush is achieved O RING BEARING SNAP RING BEARING RACE 8 To assemble the cage assembly place the large Snap ring in its mounting area in cage Press Small race to snap ring from the outside 9 Press large race into cap from back side SNAP RING 10 Place small snap ring on shaft 11 Press roller bearing on shaft to back side of snap ring Do not use shim Install woodruff key 98 12 13 15 To achieve proper pre load on bearings place IF REQUIRED Press large shim and new large roller bearing on to gear using inner bearing race Place shaft into proper position in cage push gear with bearing onto shaft ROTATE CAGE WHILE TIGHTENING the outboard side of shaft in protected vice Begin to tighten nut on gear side while turning cage until a very slight drag is achieved on the cage housing with no end play Parts must spin freely After loading to the bearing is done place new O ring around the outer diameter of cage and position in case Reinstall bolts tighten and torque to 200 in lbs 1
131. r 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 NOTE As all the gears are placed back into the assembly each should be packed with Bentonite grease LARGE BUSHING wh L uc n _ m a e i Et ED Le revere a N Itt M LIDET MI Then place a thrust washer on each end of the countershaft and a bushing on the end with the largest gear Place a larger thrust washer next to the smallest shifting gear then the bronze bushing and then an O ring NOTE Some units will use a stepped thrust washer place the washer onto the shaft so that the step in the washer Is out and away from the shifting gears The end of the shifter brake shaft end opposite the shifting gears has a spline Install the spur gear that drives the output gear onto this spline Then the thrust washer bushing and O ring 39 10 11 12 WASHER BUSHING To assemble the output shaft assembly place a washer and then the bronze bushing with collar flat down next to the pinion Place output gear over pinion as in picture There is a washer on outside of gear After both shafts are completed place the flanged bushings on each end Notice one is larger than the other NOTE That the V notch on the bushing fits into recess V in
132. rs out F 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 sprocketis also turned 180 which places 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 ein menu f SECTION 9 930 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to the many variations of equipment braking systems adjustment and repair to the components and linkages are not considered warranty NDEX BALL SPRING AND COVER CASE X SCREWS NEUTRAL START SWITCH LOCATION OPTIONAL BRAKE BRACKET SCREWS BRAKE CAN BE ON RIGHT OR ON LEFT SIDE A GENERAL The 930 series transaxle is very similar to the 920 series The 930 series will be available in 3 through 7 speeds forward and 1 speed reverse The model pictured throughout this section Is the most popular type there are models which operate in the opposite direction wi
133. s Install new brakeshaft oil seal using sleeve number 670179 Install new axle support oil seals using sleeve number 670179 Add 2 3 4 pints 44 oz Oil S A E EP 90 before securing hydrostatic drive to the 1300 series unit Clean mounting surfaces and use a new gasket between the units Torque 4 mounting bolts to 90 to 100 inch pounds 79 ein or CHAPTER 7 REDUCTION GEAR AND DIFFERENTIAL UNITS SECTION 1 2400 SERIES A 2400 SERIES d Align the driveshaft of the hydrostatic unit to the l coupling and press the units together Secure the The 2400 Series transaxle is a gear reduction unit units in assembly with three socket head capscrews which is powered by a hydrostatic pump torqued to the standard for the bolt being used SEPARATING AND COMBINING HYDROSTATIC UNIT AND 2400 1 DISASSEMBLY The two parts should be removed from the vehicle VEHICLE MOUNTING HOLES HYDROSTATIC UNIT together MOUNTING HOL i COVER i BRAKE SHAFT INPUT SHAFT LEFT SIDE HERE AXLE SUPPORT RETAINING BOLTS LONG AXLE SUPPORT oN lg es CASE 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 a Clean axles of burrs rust and sharp edges MOUNTING SCREWS 3 b Remove axle supports Be sure to note in which position and to which side they attach a To separ
134. s To service bearings refer to the Chapter on bearing service 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 press ram D INSPECTION AND REPAIR l Inspect case and cover for cracks stripped threads marred sealing surfaces and bearing condition Cause of any oil leakage should be corrected If parts cannot be repaired replace them Check shafts and gears for worn or chipped teeth Check bearing surfaces for scratches which might affect oil seal performance Check for wear Check needle bearing for presence seal and smoothness Also be sure bearings are not corroded or rusty Replace bearings of doubtful condition Check differential for rigidity Wobble indicates wear Refer to the Chapter on differentials for Service REASSEMBLY When installing axle support be sure case and cover alignment is true with the press Press Sup ports in until flanged surfaces contact case and cover Install differential and output shaft Simultaneously Position gear 3 4 I D spacer and thrust washer on shaft Center one 3 4 I D thrust washer over case needle bearing then install brakeshaft gear and other 1 1 8 I D thrust washer Position a new gasket on the mounting surface of the case then install cover Align cover and case by tapping dowel pins into cover and secure with lockscrews torqued to 10 ft Ib
135. s 180 216 Bolt 1 4 20 Bearing Cap 820 Series 90 100 Bolt 1 4 20 Differential 820 Series 84 120 Bolt 1 4 20 Brake Disc 820 e 85 110 Bolt 1 4 20 Case to Cover 1200 Series 8 10 10 9 13 6 Bolt 1 4 20 Shift Lever Housing 1200 Series 7 9 9 5 12 2 Bolt 1 4 20 Differential 1200 Series 7 10 9 5 13 6 Bolt 1 4 20 ase to a 1300 eles 90 110 7 5 9 2 10 2 12 5 Bolt 1 4 20 Case to 1400 Series TO 9 13 6 Bolt 1 4 20 Shift Lever Housing 1400 Series 9 5 12 2 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 13 6 Bolt5 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 10 9 13 6 Bolt 1 4 20 Axle Support Housing 2400 Series 10 9 13 6 Bolt 1 4 20 Differential 2400 Series 9 5 13 6 Bolt 5 16 18 Case to Cover 2500 Series 180 216 20 4 24 5 Bolt 3 8 16 Differential 2500 amp 2600 Series 420 480 47 6 54 4 Bolt 1 2 13 Axle Support Housing 2500 amp 2600 Series 720 780 81 6 88 4 Screws No 10 24 Cover R A D 20 24 1 6 2 2 2 2 Bolts 1 4 20 Retainer Cap R A D 90 110 7 5 9 2 10 2 12 5 NOTE On all units containing two jam nuts securing brake lever Hold bottom nut and torque top nut to 100
136. same loss of power symptom as overheating Typically the unit which has a slipping belt will exhibita 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 63 tan menu 3 Leakage The VST and 1800 Series have two oil reservoirs which can be checked for diagnostic purposes The first is the pump and motor expansion bellows With a small diameter blunt or round nose probe check the bellows depth through the center vent hole Proper depth from the edge of that hole is 3 1 4 3 1 2 inches 8 25 8 9 cm The second chamber is for the output gears including the differential FIRST make sure the tractor is level then remove the drain fill plug NOTE Some units that do not have differential disconnect will have two plugs We recommend using only the primary plug With a small pocket rule insert until you touch bottom of case You can then remove it and check for 1 4 3 8 inches 6 5 9 5 mm contact this is full at its 8 oz capacity 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
137. screw Torque to 10 ft lbs Install axle seals using sleeve and driver Install axle supports Be sure that the mounting pad position is correct before tightening down cap screws to 13 ft lbs Install a new gasket and shift lever housing Torque screws to 10 ft Ibs Be sure the shift lever is in the proper position to allow shifting mein menu E 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 oil All other units fill with 2 pints oil 67 mein on CHAPTER 5 FOUR SPEED TRANSAXLES SECTION 1 CAUTION DECLUTCHING IS REQUIRED WHEN SHIFTING TO AVOID GEAR CLASHING AND DAMAGE A GENERAL The 2300 series transaxles have a four speed forward and one reverse transmission BRAKE SHAFT SHIFT LEVER SHIFT LEVER HOUSING MOUNTING PADS INTERNAL QUAD RING SEAL USED AT THIS POINT ROLL OR DOWL PIN Or G t SST lt CAPSCREWS TORQUE x TO 10 FT LBS e 68 2300 SERIES B DISASSEMBLY SHIFTING N 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 restofthe unit itshould be held so that a Itlies on the cover properly blocked up so that no weight rests on the brake shaft b The c
138. shaft 3 To remove components in the 2 speed with locking differential remove in following order a To remove the shifter rod and fork remove the outside bolt spring and ball Remove high range gear then shifter gear cluster and fork assembly together INPUTSHAFT GEAR SPACER b Remove input shaft assembly c Remove shifter shaft output shaft and out put gear in this order d Remove differential and lock fork assembly together 4 INSPECTION AND REPAIR a Axle Supports 1 Check roller bearings on the axles remove any rust and clean 2 Clean axle supports and inspect b Case and Cover 1 Check for leaks or cracks 2 Replace oil seals 3 Asnecessary replace needle bearings as described in the Chapter on bearing service 4 Donotreplace brake shaftseal brake shaft shifter rod and shifter differential lock seals until the unit is reassembled c Shafts and Gears 1 Check teeth for wear pitting or breakage 2 Inspect bearing surfaces for smoothness 3 Inspectgears and shafts for out of round tan menu 4 Splines should allow a smooth fit Rotate meshing parts for a better fit if binding seems excessive d Shifter Mechanism Dual Range DIFFERENTIAL LOCK FORK ASSEMBLY HI LOW SHIFT FORK AND ROD 1 Check spring for tension and ball for wear 2 Check shifter rod grooves for wear Be sure Snap ring sharp edges goes away from shifter fork on both sh
139. t for the shift keys to slide through for gear selection SHIFT WASHER Washer on which one side has a 45 inner diameter chamfer or rounded inner diameter Shift washers depress keys for shifting from one gear to another SHIFTER ASSEMBLY Consists of 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 moves on rod to position the shifter gear atan exactspot axially along the shifter shaft tan menu SHIFTER GEAR LARGE This gear transmits lst low and reverse 1st 2nd and reverse in 4 Speed units gear ratio force to the output shaft It is beveled on both sides SHIFTER GEAR SMALL This gear transmits 2nd and 3rd 3rd and 4th in a 4 speed unit gear ratio force to the output shaft Itcan have two different tooth diameters and be beveled on the outside of each or it can have a beveled spline to engage 3rd or 4th gear through a splined shaft SHIFTER HOUSING This housing contains the shift lever and must be reinstalled in the proper position to function correctly If 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 e
140. tacts flat washer and between shaft O D and bore of brake disc Brake pads and brake disc must be free of grease and oil Install brake assembly Install transaxle on equipment Adjust brake linkage to disengage when clutch is engaged Brake and linkages may vary Consult equipment owner s manual NOTE If adjusted incorrectly the brake will do one of two things A It will not brake Stop the vehicle when the brake is applied or B If adjusted too tightly a drag or continued braking effect will be evident until the brake wears out 44 ein menu f SECTION 7 915 SERIES 940 SERIES CAUTION TO AVOID PREMATURE TRANSAXLE FAILURE DECLUTCHING IS REQUIRED WHEN SHIFTING FROM NEUTRAL TO FIRST OR REVERSE FROM ANY FORWARD TO REVERSE GEAR OR WHEN OPERATING EQUIPMENT ON A HILL OR UNDER HEAVY LOAD NOTE Due to the many variations of equipment braking systems adjustment and repair to the components and linkages are not considered warranty COVER CASE HEX ami OPTIONAL INPUT OPTIONAL A 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 915 000 S peste IDENTIFICATION TA
141. the brake shaft 1 32 THICK 7 8 I D THRUST WASHER IN PLACE ON BEARING 1 32 THRUST WASHER SQUEEZE SHIFTER RODS TO HOLD A 3 SHIFTER ASSEMBLY ji i TWO GEAR TOGETHER CLUSTER AND SPACER 10 With the small gear of the three gear cluster toward the spacer install the three gear cluster and other 1 32 thick by 7 8 1 D thrust washer on the brake shaft AXLE INPUT SHAFT LOW GEAR SHAFT SPUR GEAR TURN CW 6 Installa 1 16 thick by 3 4 I D thrust washer gear and low gear idler shaft in 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 7 Center one 1 32 thick by 7 8 D thrust washer on cover shifter shaft bearing 11 Position the gasket on the cover sealing surface then install case over the differential shaft Be Sure the boss goes under gears and that edge of the case goes over the shaft rods in the Opposite manner from which it was removed 8 Install shifter assembly as a unit into the cover 72 12 Once in position if case hangs 1 2 to 1 high turn the input shaft to get gears to mesh The case should drop about 1 4 from closing SHIFTING T 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 dowels then install an
142. the reverse idler assembly will be located either above the reverse gears and held in place by bosses in the cover or below the reverse gears and held in place by bosses in the case The reverse idler assembly will always be located against the thrust of the countershaft reverse gear BEVEL GEAR SSI L135 ee 150 THRUST RETAINING RING WASHER 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 shaftis removed Tool partNo 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 below flush NOTE Needle bearings are lubricated with EP grease DO NOT USE BENTONITE GREASE For maximum gear train life use only Bentonite grease on all shafts and gears Tecumseh part number 788067B E REASSEMBLY l SNAP RING GROOVE On SHIFT WASHERS 3 Apply grease between the bearings in the cover and install the input shaft square cut seal thrust washers bevel gear and snap ring j 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 rec
143. the shaft through the cover The seal must be replaced if the Shaft is removed ein menu f 8 DIFFERENTIAL Refer to the Chapter on differentials for service Should disassembly of the differential be necessary 2 oz of bentonite grease should be placed around the gears on reassembly E REASSEMBLY NOTE Do not apply Bentonite grease to needle bearings Use any type of axle grease or its equivalent For maximum gear train life use only Bentonite grease on all shafts and gears Tecumseh part number 788067B 1 Install the input shaft and all the associated parts in the order shown on the input shaft breakdown SHIFTER BRAKE SHAFT SHIFT COLLAR SHIFT KEYS 4 2 Grease all four keyways insert keys into collar and keyways and slide onto the shifter brake Shaft LARGE LARGER RADIUS INNER SPACE TOWARD DIAMETERS SHIFT KEYS FACE EACH OTHER ia NEUTRAL aff fS on COLLARS LEJ I Sa 3 Itis easier to assemble this transaxle if the countershaft and the shifter brake shaft are assembled atthe 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 and install the larger sprocketonto the shifter brake shaft with the collar away from the shifting keys P lace the neutral spacers onto the shifter brake shaft with larger inner diameter sides facing together and the spacer
144. the shifter brake Shaft the bronze bushing and the O ring EU NLL SPUR GEAR Place the spur gear onto the splines on the other end of the shifter orake shaft The thin washer bushing and O ring conclude the assembly of these 2 shafts WASHER BUSHING OUTPUT BUSHING 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 3 shaft assemblies back into the case Make sure that the tabs of all the bushings are in their V notches in the case 51 BEVEL GEAR 10 CENTER SHAFT BEVEL PINION GEARS BULL GEAR NOTE The differential must be assembled out of the case and then placed in the case Apply Bentonite grease to axle contact areas of case 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 to 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 Iq N WET fl WL Q al o0 Install the shifter assembly and bearing strap pack the transaxle with the remaining
145. the vise jaws SHIFT LEVER SHIFT LEVER 100 SHIFT LEVER RETAINER g N 3 Fi SN i N DOWEL PIN b DOWEL PIN TYPE Locate the dowel pin holding the retainer in the housing from the outside Place a 1 4 flat face punch on the gasket surface directly over the dowel pin Strike the punch sharply but lightly with a hammer to dislodge the retainer from the shift lever housing Always use a new dowel pin for reassembly SNAP RING TYPE Use the proper compressing type tool 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 bentor worn replace When inserting a new roll pin in the ball position so that 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 that bends in the shift lever correspond to the mounting on the vehicle mein menu f 3 REASSEMBLY a 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 in the gasket surface ofthe shift lever housing and fits into a mating hole in the transaxle HANDLE END SHIFT LEVER b SNAP RING TYPE Secure parts with the snap ring Before installing the shift lever
146. ther symptoms of malfunction c Usea jack under the Peerless unit to support it s weight when attachments are removed d Remove wheels drive belts pulleys chains and other associated equipment from Peerless unit Be aware of positioning of parts Scribe mark if in doubt to be able to reassemble parts quickly e Ifshifter lever will interfere with unitin any way remove it before unit is removed f Remove attaching hardware holding Peerless unitto equipmentatcase cover axle supports shifter or by other means g With Peerless unitfree and supported remove itfrom the area of equipment to the work bench Preparing for disassembly a Visually inspect for evidence of oil seepage tampering misalignment freedom of rotating Shafts etc b Clean unit thoroughly of dirt oil debris c Remove shift housing and drain oil from unit Observe oil to see if metal particles are present d Check axle shafts carefully for smoothness Use a Stone or suitable abrasive to rub down high spots and eliminate rust or paint e Check model number atappropriate spot It is advisable to have the exploded parts view handy f ein menu f Have seal sleeves driver tools shop cloths and informational material at hand 9 OIL LEAKS SEAL AND GASKET SERVICE Peerless units contain various styles and sizes of oil seals The function of any oil seal can be l 2 3 To seal inward single lip to prevent lubricant leaks
147. thout 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 will be explained COVER CASE SCREWS B IDENTIFICATION This unithas an aluminum tag showing the model number make sure tag is not misplaced during disassembly C STEPS TO TAKE BEFORE DISASSEMBLY 1 Clean the outside surface of the transaxle 2 Position the shift lever in the neutral position 3 Remove the set screw spring and index ball 4 If installed O E M option remove the neutral Start switch D DISASSEMBLY DIFFERENTIAL BEARING STRAP O ZOO De es uo Cea S Oye S OUTPUT SHAFT S ASSEMBLY 5 SHIFTER BRAKE SHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFTER ASSEMBLY LOCATION 1 Remove the hex head screws that hold the cover to the case 2 Push down on the shift lever rod while pulling cover off of the case The shifting lever may temporarily remain in the case Lift off cover 3 Remove the two brake bracket screws and remove brake assembly 4 Remove the grease from the unitas 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
148. tion and the gasket with oil to get it to lie flat presence f Other e Useseal sleeve to protectaxle supportoil seals during installation f Install axle supports correctly Do not rotate the support to a new position when pressed tight against the square O ring seal or the seal may be cut 6 AFTER ASSEMBLY a To install brake shaft oil seal use seal sleeve 670179 b To install shifter rod oil seal use seal sleeve 670206 and driver 670211 c Lubrication for all models is 7 to 8 pints of S A E Type A automatic transmission fluid When filling with fluid allow fluid to settle behind the tapered bearings into the axle supports This may necessitate filling checking and 1 Check thrust washers for wear adding The lubrication fill and check hole is 2 Check tapered roller bearings for wear and located In the case If the shrouding on the sacc of ronan vehicle does not allow access to the fill and check hole when the 2500 is installed in the 3 Replace shifter rod oil seal after assembly chassis lubrication should be filled prior to of all parts installation on vehicle If filling takes place before installing the 2500 in vehicle the unit must be 4 Check thrust bearing for wear and presence oriented or ata 90 angle to the axles There of rollers Should be no fluid leak g Replace any parts necessary d Install drive assembly according to manufacturer s instructions 80 LOW RANGE TRANSMISSION DR
149. to the Chapter on bearings and bushings D ASSEMBLY LOW GEAR SHAFT BEARING DIFFERENTIAL BRAKE SHAFT CARRIER BEARING 1 32 THICK 3 4 1 D THRUST BEARING INPUT SHAFT AND GEAR FLAT SIDE OF GEAR UP SHIFT LEVER OPENING SHIFTER ROD SOCKETS 1 Install input shaft in case Use a soft mallet to seat shaft and gear completely Often binding in the assembled unitcan be traced to a partially installed input shaft 1 32 THICK 1 1 D THRUST WASHER UNDER IDLER GEAR IDLER GEAR CHAMFERED SIDE UP AWAY FROM BEARING 2 Center one 1 32 thick by 1 I D thrust washer on the cover brake shaft needle bearing then in stall the brake shaft and gear chamfer side away from cover 1 16 THICK 15 16 D THRUST WASHER OUTPUT SHAFT AND GEAR Q OUTPUT SHAFT BEARING 3 Install the output shaft and gear after centering a 1 16 thick by 15 16 I D thrust washer on each end of the shaft 71 FOUR HEX AXLE AND BOLTS HEADS DIFFERENTIAL OUTPUT GEAR ASSEMBLY AND SHAFT BEVELED EDGE LOW GEAR SB ACER i SHAFT 9 Install the reverse idler shaft spacer and gear BEARING BRAKE SHAFT 2 GEAR CLUSTER in to the cover The beveled side of the idler gear should be down into the cover 4 Insertthe differential assembly into the cover Note that the four bolt heads should be out BRAKE SHAFT away from the output gear 5 Install the two gear cluster and spacer on
150. ts then remove the four mounting 1 Legend for the 1300 screws and separate the parts Drain oil from i A ache i Pi Support the 1300 unit Any hydrostatic repair must be a Brokechar 10 Bushing done through the equipment brand dealer 4 Needle Bearing 11 Cover 5 OutputGear 12 Differential Gear 6 OutputShaft 13 Case 7 Spacer 14 ThrustWasher B PRE DISASSEMBLY Clean the reduction unit exterior surfaces Drain lubricant then separate the reduction and hydrostatic units Check axle shafts for cutting edges and high spots Due to the hardness of the shafts a stone may be necessary to take off metal Check for Ly any evidence of oil leakage at gasket or bearing one HYDROSTATIC UNIT Surfaces a MOUNTING HOLES EQUIPMENT MOUNTING 2 Afterremoving the hydrostatic unit inspectthe Surfaces and the gears from outside unit GASKET Axle supports pressed from the inside out must be removed with the case and cover similar to the method used in the 1200 series transaxle 74 C DISASSEMBLY Remove the lockscrews and tap dowel pins outof cover Lift off cover and discard gasket Lift out brake shaft gear and thrust washers on each side of gears Lift output shaft gear spacer and thrust washer from case At the same time lift out the differential assembly NOTE No thrust washer Is located between the output shaft and case To service differential refer to the Chapter on differential
151. uction for strength and tapper roller bearing splitter and puller for longer life This unit can be either right angle drive with right or left handed rotation ora T drive Disassembly and reassembly are the same B DISASSEMBLY SNAP RING BEARING ASSEMBLY 5 Remove shaft out of cage Remove roller bearing with outside puller toward threaded side Remove snap ring 6 TO remove races simply tap out with punch and hammer The large snap ring will be leftin cage when all parts are removed 1 Clean and check all shaft ends before removing Cap and cage assembly SNAP RINGS 2 Remove the 4 input cage bolts and remove input cage assembly will follow 7 Remove the outputcap and assembly will follow When roller bearings are removed with puller discard do not reuse Also discard races 96 8 To disassemble the output shaft assembly first remove the bearing that is located under cap on shaft by using an outside puller CAUTION Do not hook puller on snap ring 9 Remove snap ring 10 On other end use the same puller and remove both the keyed gear and bearing at the same time 11 Remove snap ring SOFT PLUG 12 To remove 1 3 4 soft plug simply tap out of case Discard old plug 13 To remove races simply tap the race out of the cap and pry crush ring out The other race can be tapped out with punch and hammer If unit is not equipped with plug very carefully pry ra
152. uster Small gear and medium gear chamfers go down toward big gear Recheck positioning of thrust washers A misplacement or omission of washer can cause binding Check unit for correct assembly of parts Check unit for correct assembly of parts Input shaft spline must be fitted into gear and mustbe tapped completely into the case Re check positioning of bolts in differential must be Opposite output shaft gear except 2400 Check that seals are correctly installed UNIT IS NOISY Gearing is overly noisy chatter etc Check oil level Metallic pieces and or other foreign objects in unit Remove bits of broken metal loose washers etc Worn gears Worn bearings mainly input shaft ball bearing Remove and replace with new gears Replace bearing TROUBLE SHOOTING TABLE Continued CAUSE REMEDY UNIT J UMPS OUT OF GEAR Shifting lever improperly assembled in housing Disassemble shifting lever and check for proper assembly Teeth of gears are worn beyond tolerances Replace worn gears Spring in shifter fork weak or broken Replace spring Attaching screws for shift lever and housing Torque screws to 10 ft lbs assembly not properly torqued S hifter Brake shaft improperly assembled Reassemble properly 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
153. ve assembly Recheck and correctly position parts Axle Housing not installed or not tightened Seal retainers are not properly sealed Tighten axle housing Same items covered under heading Axles cannot be turned Same direction while unit in Neutral gear Shifting lever improperly positioned Shifting keys broken or damaged Shifting washers in backwards S hifter Brake shaft keyways damaged Shift lever housing misaligned to case Parts missing Equipment clutch not disengaging Shifter stop assembled backwards Chamfer on shift gears on wrong side Improper fit of case to cover Dowel pins not installed Gears improperly installed Input shaft not properly installed Differential installed improperly Seal retainers improperly positioned bolts Review remedy listed Determine if finger of shifting lever is correct for the unit and is correctly installed Make sure shift lever housing has required gasket Replace keys and check unit for other damage Chamfered or rounded side of washer must be toward keys Remove nicks and burrs from keyway Check if alignment marks on unitare correctly positioned Also determine if bend on shaft Is in correct position Install missing parts Adjust clutch according to equipment instruction Determine that notch in STOP aligns with shifter forks in NEUTRAL position Check that bevels on shifter gears are correct fork flanges should be toward each other On 3 gear cl
154. verse input bevel gear on the unsplined end of the Shaft with a washer and a bronze bushing to complete the reverse drive side of the countershaft The forward drive side requires tan menu the forward input bevel gear and 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 section to prevent the bevel gears from spreading Illustration 6 The countershaft is then completed by placing the remaining spur gears on the shaft smallest to largest If soacers are used they will be placed between the final spur gear and the washer and bushing NOTE The spur gears on the countershaft can be installed in either direction SPACER EA E esses TEn SS j SSS Ea SS E THRUST WASHERS ILLUSTRATION 7 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 Illustration DIFFERENTIAL ASSEMBLY L 5 gt ae ITT m nn l L m li I Ut Tn l Ta m i MAD Mi Hil ILLUSTRATION 8 6 To reassemble the differential first inspect the axle bevel gears for damage or wear If it is necessary to replace a gear the mating gears mustalso be replaced The differential must be assembled outside of the case a
155. ward 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 thrust washer bearing and thrust washer will be placed next to the largest spur gear and the spacer washer will be placed next to the reverse sprocket THRUST THRUST WASHER WASHER SPUR GEAR t i L BEARING aoh ASSEMBLY BEARING ASSEMBLY 7 Place large thrust washer nextto the lastshifting gear this may be a step washer on some models then a sleeved needle bearing with 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 NOTE Dependenton whether the brake is on the right or on the left will determine which end uses a capped sleeved needle bearing 35 36 8 SHIFTER THRUST WASHER C OUTPUT PINION SLEEVED BEARING ASSEMBLY SLEEVED BEARING ASSEMBLY OUTPUT GEAR Place the output gear on the ste
156. y 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 Use a bearing tool to press out the bearing Insert the proper tool in the bearing and with an oo press press out the bearing from the inside When installing open end needle bearings always apply pressure to the stamped side Use only recommended tools to insert bearings The opposite end of the same tool used for removal is used for replacement 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 1 Install the needle and ball bearing combination A bearing life will be extended Bearings should Hh MO e i a a prior to the be pressed into the cover 015 to 020 below WSEAS Re en ene the thrust surface The open end bearing in 2 When installing ball bearings use a tool to drive the low speed shaft of four speed transaxles 102 on the race which is encountering the restricted fit For example 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 is to be 010 below the thrust surface
157. y until the flange seats against the case and cover D ASSEMBLY l Install input shaft in case Use a soft mallet to seat shaft and gear completely Binding can occur if the shaft is driven in only part way Install the differential assembly The four cap screw heads should go away from output gear or downward SPACER 4 BEVEL EDGE DOWN A BEVEL EDGE OF TOOTH TOWARD LARGE GEAR SAN Lats A yw ig Pua V BY ED NA AN f J SINPUT SHAFT PNG AND GEAR Install the three gear cluster with the smallest gear up NOTE Bevels of small and middle gears go down toward large gear Large gear bevel is up The short spacer goes between the large and middle gears REVERSE IDLER GEAR SHAFT AND SPACER R i s y INPUT SHAFT AND GEAR Position the reverse idler shaftin the unit then install gear and spacer 6 10 11 SQUEEZE TOP OF SHIFT 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 i gt A 4 3 r 7 i THRUST WASHER SA ie SPACER Install the output shaft gear spacer and thrust washer Position a new gasket on the cover mounting Surface then install cover Align cover with the dowel pin and secure with the socket head cap

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