www.mymowerparts.com Service Manual 4x2 Utility Vehicle Poly Bed and Steel Bed NOTE: These materials are prepared for use by trained technicians who are experienced in the service and repair of equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. Such individuals should seek the assistance of an authorized service technician or dealer. Read, understand, and follow all directions when working on this equipment.
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www.mymowerparts.com TABLE OF CONTENTS Poly Bed 4 X 2 Drive System Customer Responsibilities ............................................................................................ 1 Gear Lube ..................................................................................................................... 1 Diagnosis: Confirming Transaxle Fault ......................................................................... 3 Transmission Linkages .........................................................
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www.mymowerparts.com Poly Bed 4 X 2 Drive System Poly Bed 4 X 2 Drive System ABOUT THIS SECTION: 2. GEAR LUBE This section covers the drive system and transaxle used in the Big Country utility vehicle model series 414 (37AN414J710). This model is distinguished from the 420 and 430 series by a polymer bed and the use of a different drive system. The 420 and 430 series use a Honda 18 hp. V-twin engine and a Dana transaxle. The 414 uses a drive system manufactured by Kawasaki. 2.1.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 2.9. 2.13. Remove the oil fill cap/dipstick. This will allow air to enter the transaxle faster, which will allow the gear lube to drain faster. A blocked vent can provoke oil leaks. The vent is located at the top of the transaxle housing. See Figure 2.9. 2.14. Install the drain plug and tighten it to a torque of 132 in.-lb. (15 N-m). Vent line 2.15. Add 68 fluid ounces (2.0 L) API “GL-5” hypoid gear lube, and install the oil fill cap/dipstick.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 3. DIAGNOSIS: CONFIRMING TRANSAXLE FAULT 3.1. Get as much information as possible from the customer regarding symptoms and circumstances. 3.1. Inspect the vehicle for physical damage and clues regarding the nature and cause of failure. 3.2. Carefully operate the vehicle if possible, to confirm noises and symptoms. 3.3.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.5. Shift Control There is a black plastic cover on the gearshift control. Slide it rearward, then lift it away from the gear shift control to expose the cable attachment. See Figure 4.5. 4.8. If the shift control is to be removed, the knob must be taken-off the shift lever. It threads off. See Figure 4.8. Gear shift control Plastic cover Gear shift cable Knob Figure 4.5 Spring Figure 4.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.12. Within the housing for the shifter control there is a torsion spring that returns the shift lever to the center of its travel. There is not a detent mechanism in the shifter control. See Figure 4.12. 4.16. Match-mark the shifter arm to the splined end of the shift arm shaft, then remove the clamp bolt using a 10 mm wrench. NOTE: The clamp bolt engages a groove in the shift shaft. It must be removed. 4.17.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.21. With the transmission confirmed to be in neutral by the meter or light connected to the switch, move the gearshift lever to the neutral position. Shift Control Adjustment 4.20. To adjust the shift cable, use the neutral safety switch to confirm the neutral position. See Figure 4.20. 4.22.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.29. If the Big Country vehicle exhibits symptoms indicating that the differential lock is not engaging or disengaging properly, investigation should begin with the control cable. Differential Lock Control In normal operation, a differential allows the two rear wheels to rotate at different speeds.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.37. With the cable disconnected, check the operation of the differential lock lever, and the torsion spring that returns it to the unlocked position. See Figure 4.37. 4.34. If the linkage binds, disconnect the cable to isolate the external portion of the linkage from internal transaxle components. 4.35.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.40. Tighten the cable bracket mounting bolts to a torque of 78 in-lb. (8.8 N-m) on installation. 4.46. The clevis pin that holds the differential lock control lever to the frame cannot be removed with the fuel tank secured in position. See Figure 4.46. 4.41. The cable is secured to a bracket near the front mounting point of the engine and transaxle cradle. See Figure 4.41. Move fuel tank to remove pin Note: cable routing Figure 4.46 Figure 4.41 4.47.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 4.51. When fully engaged, the differential lock arm should pull forward about 7/8” (2.22 cm) as measured at the center of the barrel on the end of the cable core. See Figure 4.51. 4.48. With the bracket removed, the fuel tank can be moved far enough back to allow the clevis pin to be removed. See Figure 4.48. Pin removal 7/8” Figure 4.48 Figure 4.51 4.49.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5. CVT DIAGNOSIS AND SERVICE: DRIVE BELT AND CLUTCHES (CVT OR CONTINUOUSLY VARIABLE TRANSMISSION) 5.1. Performance problems such as lack of power or failure to reach full speed may be caused by: engine performance issues, dragging brakes, or belt/clutch issues. 5.2.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.8. Inspection 5.3. Park the vehicle on a firm level surface, with the ignition turned off, and lift the load bed to provide access to the drive system. 5.4. Allow the exhaust system to cool before proceeding. 5.5. Inspect the CVT system air filter. The filter is located in front of the outer cover for the CVT. It is connected to the intake plenum by a molded hose, and it is connected to the outer CVT cover by a flexible hose. See Figure 5.5.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.12. Loosen the hose clamp that secures the molded hose from the air filter to the plenum. See Figure 5.12. 5.16. Disconnect the front flange of the exhaust pipe from the cylinder head using a 12 mm wrench. See Figure 5.16. Flange mount to cylinder head Exhaust pipe Figure 5.16 Figure 5.12 5.13. Remove the two bolts that hold the air filter housing to the air filter bracket using a 1/2” wrench, and remove the filter assembly. 5.17.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.19. Inspect the belt and clutches (pulleys) for obvious damage and wear: See Figure 5.19. 21 mm min. The belt should measure at least.827” (21 mm) across the outside (wide) surface (service limit). If it measures less than this it is worn, and should be replaced. • New belts should measure .906” (23 mm). • Confirm that the correct belt is on the vehicle: Cub Cadet Part # 754-04054.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.25. Confirm that the throttle cable, and the travel stops on the throttle cable are adjusted to provide the full range of travel without straining the cable: 5.26. There should be roughly 3/16” (4.8 mm) of play at the eyelet that connects the throttle cable to the throttle pedal. See Figure 5.26. 3/16” free play • The adjustment can be made through a combination of stop bolt (1/2” wrench) and throttle cable position (two 10 mm wrenches).
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.29. Hold the throttle arm against the stop screw. Adjust the stop screw to set the engine speed to 1,100 RPM + 50. NOTE: If the idle speed is set too low, the engine will stall at idle. If warm idle speed has fallen with time, check the condition of engine tune-up factors (compression, valve lash, spark plug, air filter) before making adjustment. 5.30. Release the throttle arm, then set the governed idle speed to 1,200 RPM + 50. See Figure 5.30. 5.32.
www.mymowerparts.com Poly Bed 4 X 2 Drive System CVT Removal: Belt and Pulleys 5.35. As the driving pulley compresses the belt, it is forced outward in the tapered sheave. 5.39. Remove the exhaust pipe and CVT cover as described previously in this section. NOTE: As the effective diameter of the driving pulley increases, the belt is drawn deeper into the sheave of the spring loaded driven pulley, reducing its effective diameter. The combined effect changes the drive ratio as speed goes up.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.44. If it is necessary to hold the crankshaft from turning: choose one of three methods. See Figure 5.44. • Remove the spark plug using a 13/16” (21 mm) wrench. With the piston rising on the compression stroke pack the cylinder with starter rope to act as a piston stop. • Remove the flywheel cover using 10 mm wrench, and hold the flywheel nut using a 22 mm wrench. • Use a strap wrench on the driving pulley. 5.46.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 5.50. After the belt is removed, the driven pulley can be removed: See Figure 5.50. 5.54. After the belt is removed, the driving pulley can be removed: See Figure 5.54. • Take the bolt and washer that secure the pulley onto the transaxle input shaft completely off using a 12 mm wrench. • Remove the bolt and washer securing the driving pulley to the engine crankshaft using a 14 mm wrench. • Slide the pulley off of the input shaft.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 6. 5.57. Beyond the warranty period, if a dealer chooses to service a driven clutch, service information and specialized tools are available from: TRANSAXLE REMOVAL AND REPLACEMENT The transaxle is carried on the engine/transaxle cradle, and the entire cradle moves up and down with the travel of the suspension. It pivots on a dog-bone joint to allow for some degree of axial twist in relation to the rest of the chassis, as well as up and down travel.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 6.6. Lift the bed. Remove the exhaust pipe and the CVT assembly, including the housing, as described in the CVT section of this manual. See Figure 6.6. 6.10. Remove the two bolts that hold the differential lock cable bracket to the transaxle using a 10 mm wrench. There will be enough slack in the cable to permit the barrel end to be disengaged from the differential lock arm on the transaxle. See Figure 6.10.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 6.16. Remove the bolts that fasten the spring mounts to the engine and transaxle cradle using a pair of 1/2” combination wrenches. See Figure 6.16. 6.13. Remove and discard the cotter pins securing the clevis pins into each brake cable clevis/actuator arm connection. Remove the clevis pins. See Figure 6.13. Cotter pin Clevis pin Spring mount bolts and nuts Clevis Figure 6.16 Figure 6.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 6.19. Jackstands must be placed under the frame, not the engine/transaxle cradle. See Figure 6.19. 6.21. Carefully lower the engine and transaxle cradle, until the wheels touch the ground. See Figure 6.21. (near C.G. of vehicle) Jackstands under frame Figure 6.19 Figure 6.21 NOTE: The cross member that the bracket for the dog-bone joint is attached to provides a convenient place for jackstands.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 7. TRANSAXLE INSTALLATION NOTES: 7.6. Install the CVT: 7.1. Reverse the removal procedure to install the transaxle. The following items are tips, reminders, and torque specifications. • Apply a small amount of anti-seize compound to the input shaft and the crankshaft. • 7.2. When mounting the transaxle to the cradle: • Roll the transaxle into position.
www.mymowerparts.com Poly Bed 4 X 2 Drive System Table 1: Drive System Torque Values Item Torque 8. LINK ASSEMBLY 8.1. The link assembly (aka:dogbone joint) connects the engine and transaxle cradle to the frame of the Big Country. This joint locates the front of the cradle, yet allows enough freedom of movement that the cradle can swing up and down and pivot to accommodate suspension travel. See Figure 8.1.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 8.6. 9. Remove the nut and bolt (top) that connect the link assembly to the frame using a pair of 15/16” wrenches. See Figure 8.6. TRANSAXLE REPAIRS Axle Assemblies: NOTE: It is possible to replace axle bearings and seals without removing the transaxle from the vehicle. If this is done, inspect the axle tubes carefully. If the axle tubes have been bent by over-loading the suspension (static or shock) then a mis-alignment of the bearings may have occurred.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.5. After the wheels and brake drums are removed from the axle shafts, remove the brake shoes as described in the “Brakes” section of this manual. See Figure 9.5. 9.7. Actuating cam Brake backing plate with shoes removed Though it is not likely to require disassembly during brake or transaxle service, it is worth noting that the backing plate is an assembly. See Figure 9.7. Structural backing plate Dust cover Mounting bolts Fixed post Figure 9.5 9.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.9. When placed on the bench, take note of the orientation of the transaxle components. Match marks will ease the assembly process but the following relationships are correct: • The brake backing plates attach with the lever and cam to the rear of the transaxle. • The shock absorber mounts on the axle tubes go toward the front of the transaxle. • The spring perches are off-set toward the bottom of the axle tubes.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.15. The axle shaft will slip out of the collar. The groove on the collar engages the pin on the shift arm 9.18. If the axle shaft is stuck in the inner race of the bearing, the right side shaft can be removed with the bearing. See Figure 9.18. 9.16. The axle shafts should slip-out through the end of the axle tube that was connected to the transaxle housing. See Figure 9.16. Seal surface Shoulder Figure 9.18 9.19.
www.mymowerparts.com Poly Bed 4 X 2 Drive System • 9.20. Remove the seal from the axle tube. See Figure 9.20. Shoulder for bearing Shoulder for seal The necked-down axle shaft spreads the force over a wider area, allowing the shaft to twist over a greater portion of its length when torque is applied to it. This reduces the load on the weakest part of the shaft: the root of the spline. 9.22. Clean the axle tubes, and inspect them for: Seal • Bends, cracks, or crushes.
www.mymowerparts.com Poly Bed 4 X 2 Drive System Transaxle housing and internals: 9.29. Use the pry-point recesses that are cast into the housings to separate the the two halves of the transmission case. See Figure 9.29. 9.26. Prepare to separate the case: Clean any rust or burrs from the input shaft with emery cloth, and remove the spacer if it was not taken off previously. See Figure 9.26. Input shaft Spacer Pry point Brake adjuster spoon Figure 9.29 Figure 9.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.32. Be certain to remove all of the cleaning solvent before heating the housing or reassembling the transaxle. See Figure 9.32. 9.31. Clean the left half of the housing, and inspect the three bearings that reside in it. See Figure 9.31. Sealed bearing for input hsaft, blind Clean any solvent from behind sealed bearing Ball bearing for red.shaft, blind Differential bearing Figure 9.31 Figure 9.32 • The largest bearing supports the differential.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.35. Lift the 51-tooth sprocket off of the reduction shaft along with the 19-tooth sprocket from the input shaft and the link-belt reverse chain. See Figure 9.35. 19-tooth reverse sprocket 9.37. The shift collar is trapped onto the input shaft by the shift lever. To remove the shift lever, it is easiest to remove the detent assembly and safety switch. See Figure 9.37. 51-tooth reverse sprocket Shift collar Shift lever Detent Safety switch Figure 9.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.43. The differential can be easily lifted out of the transaxle as an assembly, at this point. See Figure 9.43. 9.40. Use a magnet to remove the pin that retains the shift lever. See Figure 9.40. Differential Retaining pin Shift lever Figure 9.40 Figure 9.43 9.41. After the pin is removed, slide the shift arm into its bore to retract the pin from the groove in the shift collar. 9.44.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.46. Like the input shaft, it will be necessary to clean any rust from the exterior part of the shift lever before it is removed. See Figure 9.46. 9.49. Remove and discard the input shaft seal and the shift lever seal. Replace them with new seals. See Figure 9.49. Input shaft seal Vent barb Shift lever seal Figure 9.46 Figure 9.49 9.47. The shift lever can be removed through the inside of the housing.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.54. Inspect the bearing surfaces on the input shaft and 24-tooth forward gear. See Figure 9.54. 9.51. A 28mm circlip holds the 55-tooth forward gear to the reduction shaft. If either component shows wear or damage, remove this clip to separate them. See Figure 9.51. Bearing surface 28 mm Circlip securing gear Figure 9.54 Figure 9.
www.mymowerparts.com Poly Bed 4 X 2 Drive System 9.56. Clean and inspect the differential assembly. See Figure 9.56. 9.58. With the differential housing separated from the ring gear, and the cross-pin removed the miter gears can be removed from the differential. Cotter pins 9.59. With the cross-pin and miter gears removed, the bevel gear and the thrust washer can be removed for inspection or service. Cross-pin Assembly notes: 9.60.
www.mymowerparts.com Poly Bed 4 X 2 Drive System Table 2: Transaxle Torque Item Torque Ring gear to differential housing 22 ft-lb 29 N-m Differential lock shiftarm stop bolt 87 in-lb 9.8 N-m Differential lock shiftarm mounting nut 78 in-lb 8.8 N-m Transaxle housing bolts 78 in-lb 8.8 N-m Axle tube to transaxle housing 18 ft-lb 25 N-m Detent bolt 27 ft-lb 37 N-m Safety switch 87 in-lb 9.8 N-m diff. lock cable bracket 78 in-lb 8.
www.mymowerparts.com Poly Bed 4 X 2 Brake System Poly Bed 4 X 2 Brake System ABOUT THIS SECTION: This section covers brake service and adjustments on the “poly bed” Utility Vehicle 4 X 2 Model 414 (37AN414J710). 1. MAINTNANCE AND DESCRIPTION OF THE BRAKE SYSTEM: 1.1. It is important that the brakes on the Big Country vehicle be properly maintained in order for it to operate safely and dependably.
www.mymowerparts.com Poly Bed 4 X 2 Brake System 1.5. Any significant wear, damage, or binding should be addressed prior to making an operational test. NOTE: the operational test should be performed in a safe location that is free of traffic, obstacles, and hazards. 1.6. If the operator has any specific brake performance complaints, these complaints should direct the visual examination and be confirmed during the operational test.
www.mymowerparts.com Poly Bed 4 X 2 Brake System • Lift and safely support the back of the Big Country vehicle. • Remove the rear lug nuts using a 19 mm socket, and lift off the rear wheels. • Release the parking brake, if applied. 2.4. Verify the correct orientation of the brake arm on the brake actuator cam: The clevis pin on the brake lever should be visible just beyond the brake drum when viewed from the side, with the brakes released. See Figure 2.4. 2.6.
www.mymowerparts.com Poly Bed 4 X 2 Brake System 2.15. Reassemble the two springs to the new brake shoes. See Figure 2.15. 2.12. To remove the brake shoes: pivot the shoes away from the backing plate. This will reduce the spring tension. Standard shoe thickness: .257” (4.0mm) 2.13. Using either a screwdriver or a brake adjusting spoon, step the shoes over the end of the cam. See Figure 2.13. 1: Pivot out Service limit: .040” (1.0 mm) 2: Step over Figure 2.
www.mymowerparts.com Poly Bed 4 X 2 Brake System 2.20. Position the brake drums on the axles, then secure them with the hub nuts and washers. See Figure 2.20. 2.18. Confirm that the shoes and springs are properly seated. See Figure 2.18. Brake drum going on Correct shoe and spring installation Washer Figure 2.18 Nut Figure 2.20 2.19. Inspect the brake drums: See Figure 2.19. 2.21. After any brake shoe or drum service, or re-oreinting of the brake actuator arms, the brake linkages should be adjusted.
www.mymowerparts.com Poly Bed 4 X 2 Brake System 3.2. 3.6. Adjust the nut and jam nut on the bolt that joins the clevis (pinned to the brake pedal arm) to the pivot pin that goes through the equalizer bracket. See Figure 3.2. Tighten the hub nuts to 110 ft-lbs. (145 N-m) and secure each with a new cotter pin. See Figure 3.6. Adjustment nut Jam nut Figure 3.6 Figure 3.2 3.3. Place a bathroom scale between your foot and the brake pedal. Depress the brake pedal and set the parking brake.
www.mymowerparts.com Poly Bed 4 X 2 Brake System 3.11. Confirm that the parking brake light illuminates on the instrument panel when the parking brake is applied, and goes out when the parking brake is released. See Figure 3.11. Figure 3.11 3.12. If necessary the parking brake switch can be adjusted in its slotted mounting bracket. See Figure 3.12. Figure 3.12 3.13. If switch adjustment fails to make the parking brake light work properly, electrical diagnosis is necessary. 3.14.
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www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 4 X 2 Drive System - (Steel Bed) ABOUT THIS SECTION: 2. GEAR LUBE This section covers the drive system and transaxle used in the Big Country utility vehicle model series 420 and 430. There was also a low-volume series 410 that used the same transaxle without the differential lock feature. The information in this section does not specifically cover series 410, but is applicable to it.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 2.10. A blocked vent can provoke oil leaks. The vent is located at the top of the transaxle housing. See Figure 2.10. Vent 3. DIAGNOSIS: CONFIRMING TRANSAXLE FAULT 3.1. Get as much information as possible from the customer regarding symptoms and circumstances. 3.1. Inspect the vehicle for physical damage and clues regarding the nature and cause of failure. 3.2. Carefully operate the vehicle if possible, to confirm noises and symptoms. 3.3.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 3.6. An extremely bad axle bearing can mimic a dragging brake. If the axle shaft does not run concentric to the axle tube that the brake is mounted to, the brake drum will rub on the shoes when the brakes are fully released. This will produce sluggish vehicle response and a grinding noise from the bearing. 3.7.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 4.6. Start the engine and check idle speed. The engine should idle at 1,400 RPM + 150. Correct the idle speed if it is not in this range. If it is higher, the clutch will drag. 4.7. The idle speed is controlled by the amount of tension on the small spring on the governor linkage. See Figure 4.7. • If the throttle stop is set too low, the engine may stall when load is suddenly removed at the same time the throttle is returned to idle. 4.9.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 4.13. At around 1,400 RPM the sheaves of the driving pulley should begin to close on the belt. See Figure 4.13. 4.15. As the engine speed increases from idle speed to roughly 3,000 RPM, the sheaves of the driving (engine) pulley will close-down on the belt. See Figure 4.15.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 4.16. The ratio change should be fully accomplished by 3,000 RPM. Beyond this speed, increases in vehicle speed are directly proportional to increases in engine speed. See Figure 4.16. 5. CVT REMOVAL: DRIVEN PULLEY 5.1. To remove the driven pulley, begin by removing the bolt that holds it to the input shaft of the transaxle using a 3/4” wrench.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 5.5. Key points to inspect on the driven pulley are the ramp surfaces on the cams, and the polymer buttons that ride against the ramps. See Figure 5.5. 6. CVT REMOVAL: DRIVING PULLEY 6.1. Disconnect and ground the spark plug H.T. leads. 6.2. Carefully pry the plastic plug out of the center of the clutch cover. See Figure 6.2. Plastic Plug Buttons Ramp Surface of Cam Figure 5.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 6.4. Remove the drive belt. 6.8. 6.5. After the center bolt is loosened, remove the three screws that hold the cover onto the driving pulley. If the driven clutch does not function properly, replace it as a complete unit. • Slide the cover off of the driving pulley. There is not enough clearance to remove the driving pulley with the cover in place. See Figure 6.6.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 7. TRANSAXLE REMOVAL AND REPLACEMENT 7.8. The transaxle is carried on the engine/transaxle cradle, and the entire cradle moves up and down with the travel of the suspension. It pivots on a dog-bone joint to allow for some degree of axial twist in relation to the rest of the chassis, as well as up and down travel. The engine and transaxle cradle maintains correct alignment and spacing between the engine and the transaxle.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 7.16. Lift the differential lock actuator and bracket out of the way. It is not necessary to disconnect the vacuum lines nor the vent lines. 7.12. Carefully roll the drive belt off of the driven pulley on the transaxle. See Figure 7.12. Drive Belt 7.17. Unplug the neutral switch wires from the neutral switch, located on top of the forward-neutralreverse actuator mounting bracket. 7.18.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 7.21. Lift up on the bracket to remove it from the transaxle, complete with the actuator and the vacuum reservoir (the black sphere mounted to the top of the bracket). It is not necessary to disconnect the vacuum lines from the reservoir or the actuator. 7.24. Remove the U-bolts holding each spring to each axle tube using a 9/16” wrench. See Figure 7.24. 7.22. Install the drain and fill plugs, remove the drain pan and lower the bed. 7.23.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 7.32. Lower the jack completely, tip the front of the transaxle up so that the housing clears the hitch receiver gusset on the cradle, and roll the transaxle clear of the cradle on it’s own two wheels. See Figure 7.32. 7.29. Remove the bolt that connects the front of the transaxle housing to the torque bracket on the engine/transaxle cradle using a 3/8” wrench and at 7/16” wrench. See Figure 7.29. Tire Torque Bracket Transaxle Figure 7.29 Figure 7.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 8. TRANSAXLE INSTALLATION NOTES: • Differential lock actuator bracket bolts: 8.1. Reverse the removal procedure to install the transaxle. The following items are tips, reminders, and torque specifications. • Shift wedge screw: 20 + 5 in.-lbs. • Bracket: f-n-r actuator, vacuum reservoir, and neutral switch, top:72 + 10 in.-lbs. • Bracket: f-n-r actuator, vacuum reservoir, and neutral switch, side: 96 + 10 in.-lbs. • U-bolts: 23 + 3 ft.-lbs.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 9. LINK ASSEMBLY 9.1. The link assembly (aka:dogbone joint) connects the engine and transaxle cradle to the frame of the Big Country. This joint locates the front of the cradle, yet allows enough freedom of movement that the cradle can swing up and down and pivot axially to accommodate suspension travel. See Figure 9.1. 9.4. Open the hood, and disconnect the negative battery cable.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 10. TRANSAXLE ORIENTATION 10.5. The top two holes for the bolts that connect the left and right halves of the housing will be vacant. The bracket that supports the vacuum reservoir, the F-N-R actuator, and the neutral switch is secured to these points. The bracket is also bolted to two mounting bosses on the front of the right side housing. 10.1. The transaxle is a Dana / Spicer model H12 FNR.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 11. 10.9. The F-N-R shift shaft is located on the front surface of the housing. A 5/16” wrench spans the flats of the double-D shaft, and can be used in place of the shift wedge. See Figure 10.9. TRANSAXLE DISASSEMBLY: AXLE TUBE REMOVAL AND CASE SEPARATION 11.1. With the drained transaxle positioned on a stable workbench, remove the six bolts that hold the right axle tube and differential lock housing to the transaxle housing using a 9/16” wrench.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 11.4. Remove the detent set screw using a straightblade screwdriver. Retrieve the detent ball and spring from the detent screw bore using a magnet. See Figure 11.4. 11.7. Use the square recessed pry-points to separate the housing halves. See Figure 11.7. Detent Ball and Spring Magnet Figure 11.7 Figure 11.4 11.8. Separate the differential lock housing from the right side transaxle housing. 11.5.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 12. TRANSAXLE DISASSEMBLY: GEAR SET REMOVAL AND DISASSEMBLY 12.4. Lift the input shaft and thin thrust washer (.030” thick) from the housing. See Figure 12.4. 12.1. Carefully lift the differential and ring gear assembly out of the left side housing. Set it aside in a clean, safe place. See Figure 12.1. .030” Thick Thrust Washer Input Shaft Differential and Ring Gear Ass’y. Intermediate Shaft Input Shaft Fixed shaft Figure 12.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 12.6. Lift the reverse gear off of the intermediate shaft. See Figure 12.6. Intermediate Shaft Recessed Side 12.8. Remove the intermediate shaft. See Figure 12.8. Intermediate Shaft Reverse Gear Forward Gear (Recessed Side Faces Shift Collar) Shift Collar Figure 12.8 Figure 12.6 12.9. Lift the forward gear out of the housing. The forward gear has a smaller I.D. and a larger O.D. than the reverse gear does. See Figure 12.9.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 12.14. The input shaft bearing can be driven out of the housing. See Figure 12.14. 12.11. Push the shift actuator into the case, and remove it. See Figure 12.11. Bore for Shift Shaft Shift Actuator Input Shaft Bearing Figure 12.11 Figure 12.14 NOTE: The input shaft seal may be pushed through as well. There is not a shoulder in the bore. 12.12. Remove the seals from the case.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 12.16. Careful application of a propane torch (NOT oxyaccetelene), or heating the housing in an oven for about ten minutes at 250 deg. F. will expand the alloy housing faster than the steel bearing, allowing for easy removal of the bearing. 12.18. Replace any suspect parts and assemble the transaxle.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 13. 13.3. Lift the ring gear off of the differential. See Figure 13.3. TRANSAXLE DISASSEMBLY: DIFFERENTIAL 13.1. Position the differential assembly so that it rests on the differential lock dogs. The nuts on the ring-gear bolts should face up. Differential Housing (ring gear removed) 13.2. Remove the four bolts that hold the ring gear to the differential assembly using a pair of 9/16” wrenches. See Figure 13.2. Ring Gear Figure 13.3 13.4.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 13.7. If it is necessary to remove the bearing, use a bearing puller. See Figure 13.7. 13.10. Lift the miter gears and thrust washers out of the differential housing. See Figure 13.10. Cross-shaft Miter Gears Bearing Puller Thrust Washers Figure 13.7 Figure 13.10 13.8. Position the differential housing so that a flatnosed drift can be used to drive-out the tension pin that secures the cross-shaft. 13.11.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 13.13. If it is necessary to remove the bearing, use a bearing puller. See Figure 13.13. 14. TRANSAXLE: AXLE TUBES 14.1. If brake drum has not already been removed from the axle tube, perform the following steps: Gear Puller 14.2. Remove the brake drum. See Figure 14.2. Speed Nut Brake Drum Figure 13.13 Figure 14.2 NOTE: On transaxles that have never had the brake drum removed, there may be a speed nut on one of the studs.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 14.6. Slide the axle shaft, bearing, and brake bracket assembly out of the axle tube. See Figure 14.6. 14.4. Remove the brake shoes: • Release the small blue tension spring adjacent to the brake adjuster. • Remove the brake adjuster • Pry the tail of each torsion spring over the lip that it seats behind on the cast brake bracket. • Lift away the shoes and springs. 14.5.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 14.12. The bearing must be pressed off of the shoulder on the axle. The plastic dust cover may separate from its metal mounting plate in the process. See Figure 14.12. 14.10. Drill a small (1/8” or less) pilot hole into the outside edge of the retaining ring. Drill most of the way through the ring, but do not drill into the axle shaft. Enlarge the hole with a 1/4” bit. See Figure 14.10. Figure 14.12 Figure 14.10 14.13.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 14.16. Clean the axle, apply a small amount of motor oil or wheel bearing grease to the surface that the axle bearing outer seal rides on, and install a new seal onto the axle. The side of the seal with the embossed words “THIS SIDE OUT” should face the wheel flange. NOTE: To orient the brake bracket assembly to the axle tube and dust cover: 14.17. Position the brake bracket assembly, then the dust cover assembly on the axle.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 15. 15.3. Remove the two screws holding the air filter base to the fan cover using an 8mm driver. Remove the two screws that hold the air filter base to the carburetor using a 10 mm driver. See Figure 15.3. IN CRADLE ENGINE SERVICE NOTE: Basic maintenance, valve adjustment, and fuel system repair can be easily accomplished without removing the engine from the vehicle.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 15.9. Remove the fuel pump bracket from the intake manifold using a 10 mm socket. See Figure 15.9. 15.6. Remove the three screws securing the grid screen to the grid screen holder using a 10 mm wrench. Remove the grid screen. See Figure 15.6. Grid Screen Screws Figure 15.9 Figure 15.6 15.10. Note the position of the hoses that connect to the fuel pump. Disconnect the hoses, and remove the fuel pump. See Figure 15.10. 15.7.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) Valve Adjustment 15.11. The fuel pump can be tested on the bench using a hand operated vacuum pump to confirm the initial tests. See Figure 15.11. Valve lash adjustment should be checked annually, or every 300 hours of operation, whichever comes first. If clatter is heard from the engine during operation, valve lash should be checked. 15.13. Park the Big country on firm level ground, and raise the bed to provide access to the engine. 15.14.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 15.18. Rotate the engine crankshaft manually to locate top dead center (TDC) on the compression stroke for cylinder #1 (front cylinder). See Figure 15.18. • Rotating the crankshaft clockwise (seen from the fan side of the engine) will produce a puff of air from the spark plug hole just before this point. • TDC on the compression stroke can be confirmed by the valves being closed.
www.mymowerparts.com 4 X 2 Drive System - (Steel Bed) 15.23. Adjust the clearance on cylinder # 2. 15.24. Install the valve cover. See Figure 15.24. Figure 15.24 15.25. Install both spark plugs, and connect the high tension leads. 15.26. Lower the bed. 15.27. Test run the vehicle before returning it to service.
