Service manual

Poly Bed 4 X 2 Drive System
Customer Responsibilities ............................................................................................ 1
Gear Lube ..................................................................................................................... 1
Diagnosis: Confirming Transaxle Fault ......................................................................... 3
Transmission Linkages ................................................................................................. 3
Diagnosis and Service: Drive Belt and Clutches
(CVT or Continuously Variable Transmission) ...................................................11
Transaxle Removal and Replacement ........................................................................ 20
Transaxle Installation Notes: .......................................................................................24
Link Assembly ............................................................................................................. 25
Transaxle Repairs ....................................................................................................... 26
Poly Bed 4 X 2 Brake System
Maintnance and Description of the Brake System ...................................................... 39
Complete Inspection (Drum and Shoe Removal) ...................................................... 40
Brake Adjustment (under the hood) 43
4 X 2 Drive System - (Steel Bed)
Customer Responsibilities .......................................................................................... 47
Gear Lube ................................................................................................................... 47
Diagnosis: Confirming Transaxle Fault ....................................................................... 48
Diagnosis and Service: Drive Belt and Clutches
(CVTor Continuously Variable Transmission) ......................................................49
CVT Removal: Driven Pulley ...................................................................................... 52
CVT Removal: Driving Pulley ......................................................................................53
Transaxle Removal and Replacement ........................................................................ 55
Transaxle Installation Notes: .......................................................................................59
Link Assembly ............................................................................................................. 60
Transaxle Orientation ..................................................................................................61
Transaxle Disassembly: Axle tube Removal and Case Separation ............................ 62
Transaxle Disassembly: Gear Set Removal and Disassembly ................................... 64
Transaxle Disassembly: Differential ............................................................................ 68
Transaxle: Axle Tubes ................................................................................................ 70
In-cradle Engine Service ............................................................................................. 74
TABLE OF CONTENTS
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