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Chapter 2- Drive System: CVT and Transfer Case

46

DRIVE SYSTEM BENCH SERVICE:                    

TRANSFER CASE INSPECTION

1.

Clean and inspect the case and all internal parts.

NOTE: 

Most of the inspection process is visual 

or tactile.  A limited amount of measurement is 
necessary, mostly to confirm whether a part that 
is usually worn is still serviceable.  

1a.    Clean all sealant from the mating surfaces 

and clean all lubricant and dirt from the 
internal and external surfaces.

CAUTION: 

If the cases are cleaned in solvent, 

with the bearings in-place, all solvent must be 
cleaned from the bearings.  Pay particular atten-
tion to the blind bearings.  Any solvent that 
remains in the transfer case will dramatically cut 
the viscosity of the new gear lube, shortening 
the life of the freshly rebuilt transfer case.

1b.    If the cases are cleaned using detergent 

and water, with the bearings in-place, 
completely dry the bearings and spray 
them with a suitable lubricant such as Cub 
Cadet Penetrating Oil (P/N: 737-3037) to 
displace any remaining water.

1c.     Check the housings for cracks, damage to 

machined surfaces, stripped threads.

1d.    Check the vent: it should pass air.

1e.    Check the bearings for: See Figure 2.107.

•

Rough rotation: rotate them, feel and listen

•

Looseness: work the inner race and check for 
play.

•

Discoloration or obvious signs of damage.

2.

Check the middle shaft gears:                    See 
Figure 2.108. 

2a.     The gear teeth are unlikely to be hurt 

except in cases of extreme contamination, 
corrosion or foreign object damage.  In 
any of these cases the transfer case is 
likely unfeasible to repair.

2b.     Check that the dog teeth on the shaft, 

gear, and shift collar are not damaged.

NOTE: 

   If the teeth are damaged the cause of 

the damage must be corrected.  Possible causes 
include: operator abuse by shifting gears while 
the vehicle is in motion, or shift linkage issues.

2c.     The low forward and reverse gears on the 

middle shaft both have bearing-material 
inserts.  Check the inserts for wear.

2d.     Check the washers: See Figure 2.109.

Figure 2.107

Check bearing 
in housing

Figure 2.108

Gear teeth

(serrations)

Dog teeth

Shift collar

Gear

Figure 2.109

Bearing material
inserts

.030” washers
Replace if worn to less
than .025” (.64mm).

Reverse   Low range
gear        (forward) gear

Summary of Contents for Volunteer 4x4 Utility Vehicle

Page 1: ...e contents of the product s Oper ators Manual supplied with the equipment No liability can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these inst...

Page 2: ......

Page 3: ...entials 89 Chapter 4 Front Suspension and Steering 123 Chapter 5 Rear Suspension 159 Chapter 6 Hydraulic Brakes 173 Chapter 7 Kohler Engine Service Access and Fuel System 195 Kohler Engine Speed and Throttle Adjustment Addendum 215 Chapter 8 Caterpillar Engine and Related Systems 219 Chapter 9 Electrical 275 Addendum Front Drive System Differential Gearcase Hillard 323 Table of Contents ...

Page 4: ......

Page 5: ...Kohler power See Figure 1 2 Big Country 6X4 Figure 1 1 Figure 1 2 4X2 Steel Bed Poly bed 4X2 For 2005 a lighter duty version of the 4X2 was intro duced using a plastic cargo box and a 9 5 H P drives system sourced from Kawasaki See Figure 1 3 All of these first generation utility vehicles share a com mon structure from the cargo box forward The 6X4 carries a fully enclosed rear structure with swin...

Page 6: ...ers the second generation Cub Cadet Utility Vehicles more specifically and in greater depth than the origanal Shop Handbook The content in this manual supersedes any con tent in the handbook Detailed service information about the engine will be provided by the engine manufacturer in most cases Disclaimer This manual was written using second generation vehicle The information contained in this hand...

Page 7: ...exity and of reassembly and by the potential for unsafe conditions to arise from mis takes made in assembly Some instructions may refer to other parts of the man ual for subsidiary procedures This avoids repeating the same procedure two or three times in the manual 4 LIFTING AND SUPPORTING CAUTION Use common sense and safety when lifting and supporting any equipment Always work on a firm level sur...

Page 8: ...ame See Figure 1 7 Jack stands will safely support the front of the vehicle if positioned beneath the frame where the front out rig ger extends to meet the base of the OPS See Figure 1 8 Alternatively the vehicle may be lifted by positioning a jack along the outer frame channel where the rear out rigger extends to meet the base of the OPS See Figure 1 9 NOTE The center of gravity for the vehicle i...

Page 9: ...the driving pulley increases the belt has less available length to reach the driven pulley The sheaves of the driven pulley is spring loaded so that it can absorb the additional ten sion An additional effect is that the belt is drawn deeper into the sheaves reducing the effective diameter of the driven pulley Reducing the diameter of the driven pulley fur ther reduces the drive ratio Figure 1 10 C...

Page 10: ...r case at their own discretion The remainder of the drive system CVT drive shafts axles differentials is purchased from outside ven dors If any of these items fail in the first two years they should be removed and replaced with a complete unit The only exception to this may be the axles Rzeppa Constant Velocity joints may be available to repair rather than replace axles Service intent has not been...

Page 11: ...essary if the belt is to be replaced without removing both pulleys The screw can be purchased locally and modified using a thread die See Figure 1 14 7 2 The second tool that is necessary to service the drive system is a puller that draws the driving clutch off of the engine crankshaft See Figure 1 15 Figure 1 14 Figure 1 15 Driving pulley removal tool Part number 759 04111 7 3 A pulley alignment ...

Page 12: ...Chapter 1 Introduction 8 ...

Page 13: ... not warrantable replacement will be at the customer s expense Drive system components other than the CVT and transfer case are covered in greater depth in the Drive shafts Axles and Differentials chapter of this manual CVT AND TRANSFER CASE OPERATION 1 The transfer case contains a relatively conven tional three shaft gear set providing Neutral Reverse Forward and Forward Low range 2 The variation...

Page 14: ...mitted to the driven element at idle speed See Figure 2 2 5b At about 1 400 RPM the sheaves move closer to each other As they do they touch the sides of the belt and begin to transmit power See Figure 2 3 The sheaves are moved by fly weights within the driving element housing Centrifugal force drives the fly weights out The fly weights are levered against the sheave forcing it inward 5c As the eng...

Page 15: ...he expense of ground speed 5d As the belt is forced outward on the sheaves of the driving element the driven element spread allowing the belt to be drawn deeper in See Figure 2 5 5e As the belt is drawn deeper into the driven pulley two things are accomplished Belt tension is held constant even though the effective size of the driving pulley changes The range of available drive ratios is widened F...

Page 16: ...th the engine disable the engine 3a Disconnect and ground the spark plug wires on a gasoline engine 3b Unplug the fuel shut off solenoid on a die sel engine 3c Remove the key from the key switch 3d Preferably disconnect the ground cable from the negative terminal of the battery 4 Unless a procedure specifically requires the engine to be running the engine should be turned off for all maintenance a...

Page 17: ...er and the Caterpillar engines 1a When new the belt measures 1 335 031 33 9 8mm across the wide flat outside surface of the belt The belt is considered worn when the measurement is 1 20 30 5mm or less some degrada tion of performance may begin to occur as belt is worn to less than 1 275 32 4mm See Figure 2 9 Figure 2 9 New 1 335 33 9mm Worn 1 20 30 5mm 1b To remove the belt a 6mm 1 0 screw with a ...

Page 18: ...ess See Figure 2 14 NOTE When the belt is installed remove the screw before operating the vehicle NOTE It may be necessary to start the vehicle and rev the engine in neutral to seat the belt 2 Removal of the Driving element NOTE The driving element is most easily removed after the belt is taken off NOTE The driving element can be removed with the belt in place but installation may require the driv...

Page 19: ... of the crankshaft See Figure 2 17 CAUTION There is a tapered fit between the driving element and the crankshaft Applying force to the perimeter of the driving element will break it 3b If the belt was not previously removed it can be taken off as the driving element is removed 4 Removal of the driven element 4a Remove the belt NOTE The driving element fits on a tapered shaft It can be removed with...

Page 20: ...all at once using a simple wood block tool This method is described in the following steps Preparation and torque specs remain the same for both methods 6 Make the wood block spacer as described in the accompanying illustration See Figure 2 19 6a Prepare the CVT for installation See Figure 2 20 Clean the shafts and the surrounding area before installing the CVT Confirm the presence of the 060 1 5m...

Page 21: ...o not tighten fully at this time See Figure 2 22 Figure 2 21 Wooden tool sets spacing and holds assembly together for installation Figure 2 22 Shoulder spacer Washers Bolt Driving element 6f Secure the driven element to the input shaft using the bolt washer and shoulder spacer previously removed Do not tighten fully at this time See Figure 2 23 6g Tighten the bolts securing the pulleys to their re...

Page 22: ...Connect a DVOM or continuity light to the pair of terminals on the disconnected har ness 2c When the transfer case is in neutral there should be continuity 0 0 Ω between the two wires in the terminal NOTE There are two sets of shift forks within the transfer case Each shift fork has a safety switch associated with it When both shift forks are in the neutral position the contacts of both switches w...

Page 23: ...ustment This should not be considered complete repair Figure 2 26 Forward Neutral Reverse rod Low range rod 7 Centering the linkage See Figure 2 27 7a With the linkage disconnected the shift forks are centered in the neutral position by detent springs 7b At this point the shift arms can be locked into the neutral position by inserting a 3 16 or 5mm dowel rod through the align ment holes in the shi...

Page 24: ... 10 After the rod adjustment is done operate the linkage to confirm that the shift forks move fully to their engaged detent positions If there is insufficient travel the stops on the Hurst shift mechanism can be moved out If the linkages are over throwing the shift fork travel the stops on the Hurst shift mechanism can be moved in The stops are unlikely to need adjustment in the normal service lif...

Page 25: ... for confirmation and is not likely to need adjustment in the normal life of the vehi cle 13 If adjustment is necessary loosen the jam nut and tighten or loosen the bolt using a 9 16 wrench See Figure 2 30 Figure 2 30 Shift linkage travel stop adjustment 14 When adjustment is complete 14a Snug the jam nut 14b Move the lever into reverse 14c Repeat the adjustment in the opposite direction on the re...

Page 26: ... acceleratedbrake pad wear slack cable when brake is released Indications of impending failure corroded or frayed cable excessive travel on park brake lever before brakes engage worn brake pads 030 friction material thick ness 762mm burnt kinked or chafed cable housing loose hardware or damaged brackets mechanical damage to rotor or caliper 4 Repair any of these issues before proceeding with adjus...

Page 27: ...ithin the switch are nor mally closed As the lever is pulled up the plunger extends from the switch closing the contacts Contact closure 2 notches 7 Correct adjustment results in full engagement of the parking brake before the 5th notch but allows the lever to come up far enough to close the contacts in the switch 8 Checking adjustment See Figure 2 34 8a Make the adjustment with the key switch tur...

Page 28: ...ical burns and battery explosion 11 1 Adjustment can be made using a pair of 1 2 wrenches at the anchor point of either end of the cable See Figure 2 37 12 Lock the adjustment by snugging the jam nut against the mounting bracket 13 Test the operation of the parking brake in a safe area before returning the vehicle to service It should remain stationary with a full load on a 15 degree slope with th...

Page 29: ... accelerated wear and joint fail ure will occur Replace any damaged boot as soon as possible Clean and inspect the boots regularly Figure 2 38 Figure 2 39 3 The transfer case contains 64 fl oz 1 9 l of 80W 90 Low Foam Oil Cub Cadet P N 737 04040 See Figure 2 40 The transfer case oil should be changed after the first 5 hrs of use 50 hrs of use and at 500 hr intervals thereafter Inspect the transfer...

Page 30: ...uid level is low gear lube may be added through the fill plug near the top of the transfer case housing See Figure 2 42 6a The fill plug can be removed with a 5 8 open end wrench 6b Inspect the gear lube for debris or metal chafe then dispose of it properly 6c Add gear lube until it begins to dribble out of the level plug hole 6d Replace the fill and level plugs Snug the fill plug and tighten the ...

Page 31: ...cle 3 Release the CamlocR fasteners that secure the engine cover and remove the engine cover Figure 2 44 Attachment clip Cargo box hinge bolt 1 per side Lift assist cylinder 4 Disconnect the black cable from the negative terminal on the battery using a 10mm wrench 5 Remove the CVT belt and pulleys as described in the DRIVE SYSTEM CVT BELT AND PUL LEYS section of this manual See Figure 2 45 6 Remov...

Page 32: ...Low range shift rod from the Hurst shift mechanism by removing the hairpin clip and tugging the rod toward the left side of the vehicle NOTE Do not lose the plastic bushings 14 Confirm that the parking brake is released 15 Disconnect the parking brake cable from the parking brake caliper by removing the hairpin clip and clevis pin See Figure 2 49 16 Disconnect the transfer case safety switch har n...

Page 33: ...g a pair of 1 2 wrenches See Figure 2 52 NOTE The nuts are easily accessible through access slots in the bottom of the cradle NOTE Do NOT unbolt the transfer case from the brackets that connect it to the tray Figure 2 51 Front drive shaft Output shaft transfer case Figure 2 52 Engine transmission mounting tray Transfer case mounting bracket Unbolt here 21 Slide the transfer case forward to disenga...

Page 34: ...AFT TO FRONT DIFFERENTIAL sec tion of this manual 27e Apply a small amount of thread locking compound such as LoctiteR 242 blue to all of the screws that hold the engine transmission plate to the engine and the transfer case 27f Position the plate along with the spacer that fits between the plate and the mount ing boss on the engine and secure it with one screw to the engine and one screw to the t...

Page 35: ...PARKING BRAKE sec tion of this manual 31 Install the rear wheel and tire that were previ ously removed Apply the parking brake and tighten the lugs to the specified torque 32 Confirm that no unsafe conditions will result from the operation of the engine and drive system 32a Run test and adjust the drive system if needed 32b Check for any fluid leaks 32c Install the cargo box 32d Make a visual insp...

Page 36: ...ine NOTE It is not necessary to remove the univer sal joint guard from the plate 8 Carefully lift the plate out of the engine bay It is most easily removed through the opening under the passenger s seat 9 Confirm that the transfer case is in neutral 10 Disconnect the heavy Forward Neutral Reverse shift rod from the shift arm mounted to the trans fer case use a pair of 9 16 wrenches See Figure 2 58...

Page 37: ...ift and safely support the utility vehicle as described in the LIFTING AND SUPPORTING section of this manual 17 Drain the transfer case lube into an appropriate container as described in the DRIVE SYSTEM SERVICE LUBRICATION section of this man ual 18 Unbolt the transfer case brackets from the tray using a pair of 1 2 wrenches See Figure 2 62 NOTE The nuts are easily accessible through access slots...

Page 38: ...cket so that it can be installed in an identical position on the new transfer case See Figure 2 66 24 Installation Notes Transfer Case Alignment and Positioning 24a Apply a sparing amount of anti seize compound to the splined joints at the transfer case end of each driveshaft 24b Use a lifting apparatus to suspend the transfer case in the engine bay 24c Carefully lower the transfer case into posi ...

Page 39: ...aining electrical and mechanical connections 26a Connect the transfer case safety switch harness to the main harness confirming that it is properly routed 26b Connect the two gear shift rods NOTE Both bolts that connect the shift rods to the shift arms should be installed with the heads between the arms Both nuts should be installed outboard of the arms NOTE Both shift rods attach to the side of t...

Page 40: ... wrench and allow the fluid to drain into a clean pan See Figure 2 68 1d Remove the fill plug from the side of the transfer case using a 5 8 wrench This will let air enter the case faster speeding the draining process See Figure 2 69 1e Examine the contents of the drain pan and the residue that is stuck to the magnetic tip of the drain plug See Figure 2 70 1f If not previously removed take the was...

Page 41: ...r must be clean and in good condition Tighten the nuts according to the torque table that accompanies this section of the chapter Figure 2 72 Brake caliper bracket screws Figure 2 73 3 If the parking brake is being removed for brake replacement or other service NOTE The inner brake pad is epoxied into the caliper Because the inner pad cannot be replaced the caliper is offered only as a com plete a...

Page 42: ...es of the pads and rotor must be clean and in good condition Tighten the nuts according to the torque table that accompanies this section of the chapter NOTE Caliper operation See Figure 2 79 The caliper is actuated by a cam arm that forces a steel bullet against a heavy steel backing plate The backing plate and pad are doubleD shaped although one flat is longer than the other Figure 2 76 Outer ca...

Page 43: ...t the shift arms from the shift shafts using a 3 16 allen wrench See Figure 2 81 Figure 2 80 Adjustment screw Jam nut Cam arm Bullet Figure 2 81 Shift shafts Shift arms Shouldered socket head cap screws 5b Loosen but do not remove the nut and bolt that the Low range shift arm pivots on using a pair of 7 16 wrenches NOTE Long arm Low range 5c Remove the nut and bolt that the Forward Neutral Reverse...

Page 44: ... Figure 2 86 6c Remove the detent springs 6d Clear any sealant flash from the detent bores and remove the detent balls using a magnet if necessary 7 Separate the case halves 7a Remove the two sets of nuts and bolts that hold the case halves together through un tapped holes Use a pair of 1 2 wrenches 7b Support the transfer case by the housing with the screws that secure the case halves together fa...

Page 45: ...d the case halves together using a 1 2 wrench 7g Gently separate the case halves using the three pry points and a soft hammer if nec essary Do not pry against the mating sur faces to separate the case halves See Figure 2 90 NOTE The portion of the case that was lifted off is identified as the Left Case Half The other is the Right Case Half 8 Input shaft NOTE If new pinion gears and the middle shaf...

Page 46: ...inion that is machined into the shaft 9 Middle shaft and output shaft NOTE The middle shaft gears all have features that dictate their orientation during assembly 9a Remove and discard the square section hog ring from the end of the middle shaft See Figure 2 94 9b Lift the 40 tooth low gear off of the middle shaft along with the heavy washer that separates it from the hog ring See Figure 2 95 NOTE...

Page 47: ... collar Low gear shift shaft Figure 2 97 Spacer Output shaft Bull gear final gear 9e Lift the output shaft out of the housing See Figure 2 98 9f Lift the middle shaft assembly out of the housing See Figure 2 99 9g The middle shaft assembly consists of The middle shaft The 26 tooth final pinion The final pinion is held onto a splined section of the middle shaft by a snap ring The flat side of the p...

Page 48: ...the last gear left in the case secured by a 1 2 13 grade 8 cap screw and flat washer Remove it using a 3 4 wrench 9m The reverse idler contains a pair of roller bearings that ride on a hardened tube The tube passes through a washer that isolates the reverse idler from the case See Figure 2 103 NOTE If new input shaft or reverse idler that mates with it are installed in the transfer case orientatio...

Page 49: ...aution Figure 2 105 Right side case half Input shaft bearing 11b The left side case half contains three bear ings See Figure 2 106 The input shaft bearing fits in a shouldered bore that is open to the outside of the case The middle shaft bearing fits in a blind bore The output shaft bearing fits in a shouldered bore that is open to the outside of the case 11c The bearings that fit in the blind bor...

Page 50: ...remaining water 1c Check the housings for cracks damage to machined surfaces stripped threads 1d Check the vent it should pass air 1e Check the bearings for See Figure 2 107 Rough rotation rotate them feel and listen Looseness work the inner race and check for play Discoloration or obvious signs of damage 2 Check the middle shaft gears See Figure 2 108 2a The gear teeth are unlikely to be hurt exc...

Page 51: ... 2 111 Checking F N R shift collar 3c Inspect the shift shaft for wear on the mat ing and seal surfaces 3d Check that the snap rings are seated in their grooves If removed replace the snap rings with new ones NOTE if the shift yoke and collar show wear from a constant thrust load on the shift shaft wear scoring or discoloration the cause of the damage must be corrected It may be a operator abuse b...

Page 52: ...be operator abuse by applying force to the Hurst gear selec tor while the vehicle is in motion or it may be an issue with the linkage 5 The forward reverse and low range gears spin on the middle shaft Check the bearing contact surfaces on the middle shaft for wear See Figure 2 114 Any scratch big enough to catch a fingernail in indicates that the shaft should be polished or replaced Replace the sh...

Page 53: ...ss section of shaft adjacent to large set of dog teeth should be a minimum of 970 24 638mm See Figure 2 117 NOTE If there is significant wear to any of the bearing surfaces it is also very likely that the corresponding gear will have to be replaced The bearing surfaces on the inside diameters of the low and reverse gears are significantly softer than the bearing surface of the shaft NOTE The forwa...

Page 54: ...the high pinion The surfaces that ride in the ball bearings and seals for galling fretting and scratches 8b Damage to the shaft dictates the need to replace the corresponding bearing or gear that rides on that part of the shaft 8c Check the high gear pinion and low gear pinion for damage NOTE The gear teeth are unlikely to be hurt except in cases of extreme contamination corro sion or foreign obje...

Page 55: ...sing an appropriate arbor NOTE The bearings should be pressed only by the outer race 1d If the case is heated in hot water dry the bearings and spray them with a suitable lubricant such as Cub Cadet Penetrating Oil P N 737 3037 to displace any remaining water Figure 2 121 2 Install the reverse idler gear 2a Apply a small amount of thread locking compound such as Loctite 262 red to the threads of t...

Page 56: ...everse shift collar 3f Position the shift collar and travel stop spacer on the forward neutral reverse shift shaft assembly NOTE The forward neutral reverse shift shaft is the one with the shift yoke near the middle The spacer goes between the yoke and the detent notches in the shaft 3g Apply a small amount of grease such as Cub Cadet multi purpose grease P N 737 3034 to the shift shaft and insert...

Page 57: ...acer 22 tooth forward gear Figure 2 127 Output shaft 3l Install the spacer on the output shaft See Figure 2 128 3m Install the final pinion on the middle shaft The shoulder on the gear should face the forward high range gear The flat side faces up 3n Install the snap ring that secures the final pinion Use a new snap ring See Figure 2 129 3o Apply a small amount of anti seize com pound to the insid...

Page 58: ...gainst the low pinion See Figure 2 131 3v Install the small 030 762mm flat washer on the middle shaft against the low pinion 3w Slip a new middle shaft retaining ring over the small diameter portion of a 3 8 drive 3 8 socket Push the ring down the socket onto the large diameter portion See Figure 2 132 3x Place the socket on top of the middle shaft and drive the ring onto the shaft using a length ...

Page 59: ...but they need not be torqued Figure 2 134 Input shaft Flat washer Low pinion Figure 2 135 Bolt used as a driver Alignment dowel 4 Checking and final assembly 4a Affix a dial indicator to the input shaft so that it reads against the case See Figure 2 136 4b Work the input shaft up and down to get and end play measurement on the dial indicator End play should be less than 009 23mm without pre loadin...

Page 60: ...h in the F N R switch hole holding the shaft in neutral See Figure 2 139 4g Position the low range shift shaft the one closer to the input shaft so that it extends 2 5 1cm from the surface to the case See Figure 2 140 NOTE The notch in the low range shift shaft will be centered in the hole for the neutral safety switch indicating neutral position 4h Apply thread sealant to a neutral safety switch ...

Page 61: ...s it passes through the neutral position Continue until the shift shaft extends 1 9 16 3 97cm from the case This is forward gear Rotate the input shaft The output shaft should spin in the same direction at roughly 1 5 the speed of the input shaft Return the low gear shift shaft to neutral 4k If any of the above checks does not hold true or if any unusual noises are heard while performing the tests...

Page 62: ... special tool by modifying a lug nut P N 712 3050 Grind down the peaks between each facet until all the peak to peak measurements are less than 3 4 1 9cm Smooth the transition from the tapered seat of the lug nut to the facets 4s Fasten the lug nut to the input shaft using a 5 16 18 bolt The tapered side of the lug nut should face away from the input shaft 4t Slip the new hog ring over the lug nut...

Page 63: ...ue of 220 280 in lb 25 32 N m NOTE If the sealing gasket needs replacement it can be ordered as part number 721 04174 This part is not listed in the IPL 4ad If removed install the vent Tighten it 2 3 turns NOTE Allow RTV sealant to cure according to the sealant manufacturer s instructions before filling the case with gear lube 4ae Fill the case with 64 fl oz 1 9L of 80W 90 Low Foam Oil Cub Cadet P...

Page 64: ...be necessary to rotate the input shaft for internal gear alignment Return both shift arms to neutral when finished 6 Install the parking brake 6a Apply a small amount of thread locking compound such as Loctite 262 red to the screws that hold the caliper bracket to the case 6b Apply a small amount of ant seize com pound to the brake shaft 6c Position the brake caliper and brake rotor as one assembl...

Page 65: ...le or Medium Strength threadlocking compound such as Loctite 242 blue to the screws that hold the caliper bracket to the case Item ft lbs N m Reverse idler bolt1 32 40 43 54 Neutral safety switches2 32 36 43 49 Detent plate screw 16 21 23 Case screws 16 21 23 Adaptor housing screws3 16 21 23 Drain and level plugs 18 23 25 32 Fill plug and vent snug snug Shift arm bracket3 16 21 23 Shift arm pivot ...

Page 66: ...Chapter 2 Drive System CVT and Transfer Case 62 ...

Page 67: ...mple but specialized tools needed to loosen the belt remove the driving pulley and align the engine to the transfer case A small screw can be used to spread the sheaves of the driven element so that the belt can be removed Dimensions are in the text A clutch puller part number 759 04111 is needed to pull the driving element off of the tapered crankshaft Use the alignment tool part number 707 04878...

Page 68: ...e the parcel bin under the passenger seat and remove the parcel bin 2e Release the camlok fasteners that secure the engine cover and remove the cover 2f Unbolt the passenger s seat mounting bracket from the seat plate using a pair of 1 2 wrenches See Figure 2a 2 2g Remove the grab handle and seat plate assembly from the vehicle using a pair of 1 2 wrenches Description Qty Mounting stud driven pull...

Page 69: ... new seat bracket is vital This opening allows cooling air to enter the CVT enclosure If the supply of cooling air is restricted the CVT belt will over heat and fail Figure 2a 3 Old seat plate New seat plate Grab bar Flange brgs Figure 2a 4 Old seat bracket New seat bracket 2j Remove the three screws that hold the right rear fender to the splash shield using a 5 16 wrench See Figure 2a 5 2k Remove...

Page 70: ...ift the splash shield off of the vehicle 3 BELT REMOVAL 3a To remove the belt a 6mm 1 0 screw with a minimum thread length of 1 15 2 9cm will be required See Figure 2a 9 NOTE A 6mm screw with a thread pitch of 1 0 may be purchased locally The minimum thread length needed is longer than the threads of a standard screw of this size It will be necessary to cut threads further up the shank of the scre...

Page 71: ...in the same direction 3e As the sheaves are spread the tension on the belt will be relieved and the belt can be rolled off of the driven element pulley See Figure 2a 12 Figure 2a 11 Install screw to spread sheaves Driven pulley Figure 2a 12 orientation Arrow to maintain 4 REMOVE THE CVT PULLEYS 4a Remove the three screws holding the cover in place using a T 20 driver then remove the cover See Figu...

Page 72: ...ector in H position and set the parking brake 4g Loosen the bolt holding the driven pulley to the input shaft using a 9 16 wrench 4h Remove the bolt and washers 4i Slide the driven pulley off of the splined transfer case input shaft See Figure 2a 16 CAUTION Do not pry on the outer edge of the driven pulley It will bend ruining the pulley 5 Change back plate 5a Disconnect the heat shield from the e...

Page 73: ...e 5h Attach the heat shield to the new back plate using the 1 4 20 screws and spac ers Tighten them using a 5 16 wrench See Figure 2a 20 5i Position the new back plate connecting the engine to the transfer case See Figure 2a 21 NOTE If the new back plate does not align prop erly with the mounting holes loosen the transfer case mounting brackets from the engine transfer case tray and adjust the pos...

Page 74: ...ti seize compound may be used on the splined joint between the input shaft of the transfer case and the driven element The tapered joint between the driven element and the crankshaft may be lubricated with a small amount of multi purpose grease Cub Cadet P N 737 3034 Apply a small amount of thread locking com pound such as Loctite 262 red to the stud that will secure the driving pulley NOTE The sc...

Page 75: ...s correct install the driven pulley screw with thread locking compound such as Loctite 262 red and tighten it to 32 36 ft lb 43 49 N m Figure 2a 25 Critical corner Alignment tool Shims behind driven pulley 6g Install the cooling fan on the driving pulley securing it with the flat washer and castle nut See Figure 2a 26 6h Tighten the nut to a torque of 22 25 ft lbs 30 34 N m then secure it using th...

Page 76: ... returning all the way to rest position at idle 7 FINAL ASSEMBLY 7a Install the drain plug in the CVT cover and carefully tighten it until snug using a 1 2 wrench 7b Slip the CVT cover in through the opening inthepassengersideoftheseatbox See Figure 2a 28 7c Rotate the CVT cover down into position 7d Fasten the CVT cover to the back plate using the 12 1 4 20 self tapping screws See Figure 2a 29 7e...

Page 77: ...See Figure 2a 31 7k Install the intake tube between the bracket and the spigot on the front of the CVT cover Secure it with the hose clamp See Figure 2a 32 7l Reinstall the engine cover and parcel bin 7m Lower the work box and seats 7n Test drive the vehicle in a safe place to confirm that it operates properly before returning it to service Figure 2a 31 Opening in bottom of seat plate Tube bracket...

Page 78: ...Kohler Enclosed CVT Addendum 74 ...

Page 79: ...cialized tools needed to loosen the belt remove the driving pulley and align the pulleys A small screw can be used to spread the sheaves of the driven element so that the belt can be removed Dimensions are in the text A clutch puller part number 759 04111 is needed to pull the driving element off of the tapered crankshaft Use the alignment tool part number 707 04878 to check spacing and alignment ...

Page 80: ...r seat and remove the parcel bin 2e Release the camlok fasteners that secure the engine cover and remove the cover 2f Unbolt the passenger s seat mounting bracket from the seat plate using a pair of 1 2 wrenches Remove the seat and bracket See Figure 2b 2 NOTE It is not necessary to disconnect any fuel lines The fuel pump and filter will be moved to provide room for the CVT cover to fit into the a...

Page 81: ...vots on fit through the holes in the seat plate with the shoulders to the outside The bolts holding the grab handle to the vehicle trap the bearings in position 3c Replace the original seat bracket with the seat bracket contained in the kit Position the rear set of seat bracket mounting bolts in the bracket before bolting the seat to the bracket See Figure 2b 6 NOTE The opening in the front of the...

Page 82: ... or by contaminating the air intake tube down stream of the filter 4 BELT REMOVAL 4a To remove the belt a 6mm 1 0 screw with a minimum thread length of 1 15 2 9cm will be required See Figure 2b 9 NOTE A 6mm screw with a thread pitch of 1 0 may be purchased locally The minimum thread length needed is longer than the threads of a standard screw of this size It will be necessary to cut threads furthe...

Page 83: ...nstalled so that it rotates in the same direction 4e As the sheaves are spread the tension on the belt will be relieved and the belt can be rolled off of the driven element pulley See Figure 2b 12 Figure 2b 11 Install screw to spread sheaves Driven pulley Figure 2b 12 5 REMOVE THE CVT PULLEYS 5a Remove the three screws holding the cover in place using a T 20 driver then remove the cover See Figure...

Page 84: ...e parking brake 5g Loosen the bolt holding the driven pulley to the input shaft using a 9 16 wrench 5h Remove the bolt and washers 5i Slide the driven pulley off of the splined transfer case input shaft See Figure 2b 16 CAUTION Do not pry on the outer edge of the driven pulley It will bend ruining the pulley 6 Change back plate 6a Remove the two screws that hold the starter motor to the engine pla...

Page 85: ...sfer case adaptor 6g Position the new aluminum back plate connecting the engine to the transfer case See Figure 2b 20 NOTE If the new back plate does not align prop erly with the mounting holes loosen the transfer case mounting brackets from the engine transfer case tray and adjust the position of the transfer case DO NOT loosen the screws that hold the brackets to the transfer case 6h Apply relea...

Page 86: ...plate is properly aligned on engine and transfer case tighten all the screws See Figure 2b 23 6l Re mount the starter motor See Figure 2b 24 Apply releasable thread locking compound such as Loctite 242 blue to the screws Install the screws and lock washers that hold the starter to the engine plate tightening the screws to a torque of 22 25 ft lbs 30 34 N m Check electrical connections and insulati...

Page 87: ...shaft of the transfer case will be reused The screw that held the driving pulley to the engine crankshaft will be replaced with the dou ble ended stud Figure 2b 25 Spacers 7b Fasten the driving pulley to the crankshaft using the washer and shoulder spacer previously removed on the double ended stud Tighten it to a torque of 35 36 ft lbs 43 49 N m See Figure 2b 26 7c Secure the driven pulley to the...

Page 88: ...Roll the drive belt back onto the pulleys Refer to the marks made before the belt was removed to confirm that the direction of rotation has not been changed See Figure 2b 29 7k Remove the screw that was used to spread the sheaves of the driven pulley 7l Place the gear selector in neutral 7m Re connect the negative battery cable 7n Clip a jumper wire from the eyelet on the fuel pump ground wire to ...

Page 89: ... 4 20 self tapping screws Tighten the screws using a 3 8 wrench See Figure 2b 32 8e Mount the fuel pump to the console cup holder support See Figure 2b 33 NOTE The star washer should be located under the head of the bolt that the ground wire is attached to so that it bites through the paint to establish a good electrical ground for the fuel pump Apply a small amount of silicone grease to protect t...

Page 90: ...t the fuel filter to the frame using the 5 16 18 nuts and bolts previ ously removed 8j Use the opening in the new seat plate to locate the tube support bracket The openings in the seat plate and the bracket should be concentric 8k Mark the points to drill mounting holes for the tube support bracket 8l Center punch and drill mounting holes in the seat box using a 9 32 7mm drill bit 8m Mount the bra...

Page 91: ... See Figure 2b 38 8o Install the passenger seat and its new bracket to the new seat plate using a pair of 1 2 wrenches See Figure 2b 39 8p Reinstall the engine cover and parcel bin 8q Lower the work box and seats 8r Test drive the vehicle in a safe place to confirm that it operates properly before returning it to service Figure 2b 38 Intake tube Figure 2b 39 ...

Page 92: ...Caterpillar Enclosed CVT Addendum 88 ...

Page 93: ... drive shafts front and rear are driven whenever the transfer case is in gear whether or not four wheel drive is engaged Figure 3 1 Spicer hooke type U joint 4 The rear differential has a cast iron housing and a cable actuated locking feature See Figure 3 2 5 The front differential has an aluminum hous ing and an electrically controlled slip sensing Auto Lok feature See Figure 3 3 5a The front dif...

Page 94: ...be at the customer s expense Beyond the warranty period internal parts for the differentials will be made available so that the dealer can repair or replace them at their own discretion ADJUSTMENT DIFFERENTIAL LOCK LINKAGE 1 The differential lock lever located next to the Hurst gear selector lever operates on the rear axle only When engaged the rear drive wheels are locked together eliminating dif...

Page 95: ... or disen gage as it should the problem may be internal or the problem may be in the linkage Before removing the differential confirm that the prob lem does not lie in the linkage 7 Confirm that the linkage moves freely through its range of travel When released the center line of the pin that connects the shift fork to the linkage should be 1 1 8 32mm from the end housing that sup ports the sealed...

Page 96: ... that hold the back of the console cover A 9 16 wrench can also be used to loosen the two screws that secure the front edge of the cover through slotted holes 11d Lift the cover off to remove it 12 When the differential lock is released the pivot link is held horizontal by spring tension See Figure 3 9 13 When the differential lock is engaged the pivot link is pulled up and forward See Figure 13 0...

Page 97: ... gear lube should be changed after the first 50hrs of use and there after at 500 hr intervals Inspect the differential case vent at 100 hr inter vals A blocked vent will cause fluid loss The differential gear lube should be checked at 100 hr intervals unless fluid loss is noticed In the event of fluid loss identify and repair the leak as soon as possible to prevent catastrophic failure of the diff...

Page 98: ...k up If this occurs drain the fluid down to the correct level The differential should suffer no loss of function or longevity 6 To check the fluid in the front differential 6a Park the vehicle on a firm level surface 6b Allow the engine and drive system to cool to ambient temperature 6c Tilt the hood forward to open it 6d Clean the area surrounding the fill plug and level plug See Figure 3 14 6e R...

Page 99: ...le to provide easy access to the top of the front differ ential See Figure 3 16 3a Open the hood 3b Disconnect the headlights where the har ness plugs into the bulb holder leaving the bulb holder in the lamp 3c Remove the two internal cotter pins that hold the hood panel to the hood brackets 3d Disconnect the check cables from the hood using a 3 8 wrench 3e Slide the hood to the left of the vehicl...

Page 100: ... push in fasteners that secure the front of the driveshaft cover 6c Lift the rear of the cover and draw it back to disengage the locating tabs at the front edge Remove the driveshaft cover 7 Disconnect the driveshaft from the front differen tial NOTE The front of the drive shaft is secured to the pinion shaft on the front differential by a ten sion pin 7a Rotate the driveshaft as necessary to reac...

Page 101: ...differential mounting bolts Access from beneath the vehicle Figure 3 23 Torque bracket 9 Release the Camloc fasteners that secure the tool bin under the driver s seat and remove the tool bin 10 Remove the guard between the driven element of the CVT and the universal joint on the front driveshaft using a pair of 1 2 wrenches See Figure 3 24 NOTE The mounting tubes are on the top side of the guard T...

Page 102: ...t length of 2x4 dimensional lumber or a similar object See Figure 3 26 NOTE Be very careful not to damage the throt tle cable differential lock control wires brake line constant velocity joint boots NOTE Be careful not to disengage either con stant velocity joint 11d Maneuver the front driveshaft to clear the bulkheads and front differential and draw it forward See Figure 3 27 11e Withdraw the dri...

Page 103: ... Torque bracket to frame 12 16 FRONT HALF SHAFT REMOVAL Failure mode cause and remedy The Rzeppa type constant velocity joints at each end of the front half shafts are protected by rub ber boots If a boot gets torn the joint will be damaged quite rapidly by any foreign material that gets into the joint Replace the joint if a boot is compromised for any significant length of time Heat is the enemy ...

Page 104: ... a 19mm wrench See Figure 3 31 NOTE NOTE When removing nuts with nylon locking rings that are installed on taper fit studs loosen the nut far enough to disengage the locking fea ture before separating the tapered joint 3b Loosen the nut that holds the tie rod end to the front hub using a 19mm wrench 3c Separate the tie rod end from the hub A two jaw or three jaw puller will separate the tie rod en...

Page 105: ... 33 Lower control arm Front hub Figure 3 34 Upper ball joint Front hub 3g Use a soft drift to drive the axle out of the hub See Figure 3 35 NOTE Positioning a length of 2 X 4 dimensional lumber to brace the hub will make the job easier NOTE Disconnecting one ball joint does not provide enough clearance to allow the driveshaft to come out At this point the lower ball joint may be disconnected or th...

Page 106: ...to the frame Replace any worn hardware or components before reassembly If the self locking feature of any of the nuts is degraded replace the nuts or apply thread locking compound such as Loctite 242 blue to the threads If the locking features of nuts on the tie rod end or ball joint stud has worn replace the nut Do not use thread locking compound Assemble the front suspension by reversing the ste...

Page 107: ...nd on assembly Reverse the removal procedure to install the front drive shaft Replace any worn hardware or components before reassembly If the self locking feature of any of the nuts is degraded replace the nuts or apply thread lock ing compound such as Loctite 242 blue to the threads When installing the front differential install all of the hardware that secures the differential and torque bracke...

Page 108: ...al used in the Cub Cadet 4X4 Utility vehicle will void the warranty NOTE There are no service parts available through Cub Cadet for the front differential used on the 4X4 Utility Vehicle 1 After draining the case can be separated by removing the perimeter screws See Figure 3 39 NOTE A square section O ring fits on a lip on the left side housing sealing surface No other sealant is necessary between...

Page 109: ...rvice life of the vehicle 5 The pinion cover can be easily removed from the differential assembly See Figure 3 43 Figure 3 42 Pinion mesh adjustment screw Figure 3 43 6 The pinion shaft and bearing slip out of the hous ing once the cover is removed See Figure 3 44 NOTE The pinion shaft can be removed together with the pinion cover or separately 7 Outside of warranty if the pinion seal develops a l...

Page 110: ...7 The toothed ring engages the end of a cage that surrounds two sets of rollers See Figure 3 48 NOTE Each roller is centered in its recess in the cage by a set of springs The left side drive spool is carried in the bearing that is held behind the toothed ring One set of rollers rides on the left drive spool The right side drive spool fits into the second set of rollers A thrust bearing separates t...

Page 111: ...ed rollers fit down into the drum with the drive spools rotating freely within the rollers as long as the magnet is not energized See Figure 3 51 NOTE Cable ties are used to hold the rollers in the cage during assembly 12 Operation 12a When the magnet is energized the cage and rollers lag behind the rotating speed of the ring gear because of the drag between the toothed ring and the housing 12b Wh...

Page 112: ... their grooves to the ramps on the over run side of their grooves 14e Few operators will encounter this condi tion Of those that do only the most per ceptive will even notice it 14f If the brakes are applied or the engine has fallen to idle speed the condition will be negated by the brakes and or the dis engagement of the CVT REAR DRIVE SHAFT REMOVAL NOTE If the universal joints exhibit enough pla...

Page 113: ... install ing the drive shaft Make any needed repairs before reassembly Apply anti seize compound to the splined joints on assembly Replace any worn components before reassem bly If the self locking feature of any of the nuts is worn replace the nuts or use thread locking compound such as LoctiteR 242 blue Apply permanent thread locking compound such as Loctite 262 red to the bolts that fasten the ...

Page 114: ...zeppa joint that clicks as the steering or suspension travel through their range of motion has worn and should be replaced At the time of printing it is uncertain if replace ment axle components will be available Replacement boots may be available for instal lation on the constant velocity joints Replacement joints may be available for instal lation on the axles If replacement of a constant veloci...

Page 115: ...s Figure 3 58 Brass drift Axle nut protecting end of threads 9 Carefully pivot the hub forward pushing in on the end of the axle This will separate the hub from the axle Once separated support the hub so that it does not stress the brake line See Figure 3 59 NOTE The inner joint is easier to work with if the outer joint is free of the hub 10 Clean the area around the connection point between the a...

Page 116: ...tion to the bushings that sup port the hub If the self locking feature of any of the nuts is worn replace the nuts or use thread locking compound such as Loctite 242 blue Replace the cotter pin with a new 1 7 8 X 1 8 47 5 X 3 2mm cotter pin Reverse the removal procedure to install the rear drive shaft NOTE Tightening the nuts and bolts that hold the control arm to the frame locks the control arm b...

Page 117: ...g a 13mm wrench Figure 3 62 Rear differential Driving tension pin upwards Figure 3 63 Rear differential mounting bolts NOTE It is not strictly necessary to remove the cargo box for the remainder of this procedure but the technician may choose to do so for ease of access 5 Remove the rear differential torque bracket from the frame using a 1 2 wrench See Figure 3 64 6 Disconnect the differential loc...

Page 118: ...re 3 67 11 1 Lift the muffler and remove the rear cross mem ber from the vehicle 12 Clean the area surrounding the connection to the second axle and pop the axle loose from the differential See Figure 3 68 13 Slide the differential back to disconnect the drive shaft from the pinion shaft of the differential 14 Remove the differential from the vehicle sepa rating the second axle from the differenti...

Page 119: ... the vehicle in a safe area before return ing it to service Item ft lbs N m Hub to upper control arm 32 36 43 49 Upper control arm to frame 32 36 43 49 Axle nut 150 165 203 223 Lug nuts 65 75 88 102 REAR DIFFERENTIAL NOTE The rear differential will not be repaired in the field If there is damage to it it will be replaced as a complete unit The following section of this chapter is intended to incre...

Page 120: ...the left side large housing 2c Keep track of the number of shims on each cartridge if the differential is disassem bled See Figure 3 73 2d Beneath the input shaft seal is a crimp nut The tightness of the nut sets the pinion bearing pre load With the seal removed correct pinion bearing pre load should result in pinion shaft drag of 2 3 in lbs 23 34 N m 3 Remove the left side bearing cartridge 3a Re...

Page 121: ...ng race and the sealed bearing that sup ports the axle See Figure 3 76 Figure 3 75 Left bearing cartridge Left axle bearing Figure 3 76 Shims Bearing race Oil seal Left bearing cartridge 3f With the left bearing cartridge removed the differential carrier bearing cone is exposed See Figure 3 77 4 The right side cartridge can be removed in simi lar fashion but the differential lock shift fork passes...

Page 122: ...al components and ring gear are held together by one set of 3 8 24 gr 8 screws With the screws removed the ring gear comes off and the differential can be separated See Figure 3 81 5b If the carrier bearing is to be replaced it can be removed using a bearing puller The differential lock collar will slide off with the bearing removed See Figure 3 82 5c Four pins on the differential lock collar enga...

Page 123: ... Figure 3 83 16 tooth miter gear Splined I D 4 holes for lock pins Differential side plate 4 differential lock pins Figure 3 84 Cross pins Central block 5f With the block and cross pins removed the four 10 tooth meter gears can be lifted out of the differential body See Figure 3 85 Thrust washers are located between each 10 tooth miter gear and the differential body The 16 tooth miter gear that re...

Page 124: ...y loose than tight Confirm adjustment by checking end play of the differential A dowel rod having an outside diam eter from 3 4 to 7 8 19 22mm can be used to press against the long cross shaft in the differen tial A shorter dowel of the same size can be inserted from the opposite side providing a flat surface for a dial indictor to register against 6c Once the number of shims is correct the distri...

Page 125: ...h as Loctite 262 red 2 Apply a small amount of re leasable thread locking compound such as Loctite 242 blue 7 Operation 7a In open operation the differential allows the two rear wheels to rotate at different speeds This reduces absolute traction but improves cornering grip 7b When the differential lock is engaged four pins lock the two halves of the differential housing together This improves rear...

Page 126: ...Chapter 3 Drive System Drive Shafts and Differentials 122 ...

Page 127: ...arts As an example if a technician repairs a tie rod end that was broken in a violent encounter with a tree the alignment should be correct when the repair is completed If the toe angle is not cor rect after the tie rod end is replaced it could point to further less obvious damage If the toe angle has changed because the steering arm that is cast as part of the hub assembly has bent the hub castin...

Page 128: ...r sand where more traction is required The vehicle is used to carry delicate contents that would benefit from a softer ride Tire size and condition 1 Tire wear indications Because the vehicle is equipped with trail tires tire wear will be accelerated if the vehicle is used heavily on paved surfaces Front tread blocks that appear smeared out ward on the font surface of the tire indicate a toe in co...

Page 129: ... on a smooth dry concrete surface 2b To isolate the steering gear disconnect the tie rod ends one at a time Check the effort level required to turn the steering wheel with each tie rod separated from the steering arm If the steering is dispro portionaly easy with one tie rod discon nected check the hub to see if it rotates freely on its ball joints 2c If the steering wheel offers resistance at 90 ...

Page 130: ...side on the rear can actually raise the measured ride height Spring and damper units See Figure 4 7 Make a visual inspection for _Broken coils _Leaking fluid from the damper _Bent shaft _Loose fasteners Minor adjustments can be made to the front spring rate and resultant ride height using a pur pose built spanner Part 759 04125 to rotate the stepped lower spring perch If the ride height has fallen...

Page 131: ...ing noise when the vehicle is in motion In extreme cases worn wheel bearings may produce brake drag as the rotor does not run true in the caliper Figure 4 8 Brakes While spinning the wheels to check the wheel bearings pay attention to the amount of effort necessary to spin the wheel A wheel that does not spin easily most likely indi cates a dragging brake Symptoms A dragging brake is likely to gen...

Page 132: ...control arm bushings will produce a heavy clunk as the vehicle goes over bumps To check the control arm bushings See Figure 4 10 1 With the weight of the vehicle resting on the sus pension pry outward on the control arm from the point where it mounts to the frame 2 Repeat for each control arm bushing upper lower front rear 3 If the control arm moves easily the control arm busings are worn Tie rod ...

Page 133: ...minimum 4 6 137cm long straight edge or a 12 305cm length of string Figure 4 12 Straight 1 2 EMT conduit String Adjustable square Framer s square Alignment Specifications Alignment procedure 1 Park the vehicle on a firm flat level surface The cargo box and seats should be empty 2 Center the steering wheel bounce the vehicle and roll it back and forth to center and settle the front suspension 3 Beg...

Page 134: ...ator s or rugged terrain When the camber is correct ride height mea sured at the front bottom corner of the frame should be 10 1 2 25 4 1 25cm Minor adjustments can be made to the front spring rate and resultant ride height using a pur pose built spanner to rotate the stepped lower spring perch If the ride height has fallen beyond the range of adjustment on one side or both sides replace the sprin...

Page 135: ...limeters Figure 4 16 Toe in Toe out Toe angle reacts to braking forces Under braking the front wheels tend to toe out because the contact patch of the tires lies out board of the axis established by drawing an imaginary line between the two ball joints This line represents a virtual king pin around which the wheels rotate with steering action When drag braking is applied outboard of this line it t...

Page 136: ...ods are behind the pivot point of the wheels that imaginary line drawn between the two ball joints Lengthening either tie rod pushes the alignment in the toe in direction Shortening either tie rod pushes the alignment in the toe out direction 13 To correct the illustrated toe in condition on the left front wheel shorten the tie rod See Figure 4 19 13a Hold the tie rod using a 14mm wrench and loose...

Page 137: ...ble threads on the left and right tie rods the steering wheel itself is very likely off center 15 After making a tie rod adjustment Roll the vehicle back and forth bouncing it up and down slightly to settle the suspension Make sure the steering wheel is centered Re measure the toe angle Make further adjust ments if necessary When the toe adjustment is correct tighten the jam nut 16 To remove the s...

Page 138: ... in the toe angle adjustment section of this chapter confirm that the steering is at the center of its travel 3 Measure the distance between the head of the travel stop bolt and the point where it meets the lower control arm See Figure 4 21 The distance should be equal for both sides of the front suspension There should be 1 425 3 62cm between the two points 4 If adjustment is necessary See Figure...

Page 139: ...s See Figure 4 24 Figure 4 23 Figure 4 24 Inner fender well Frame Spring and damper unit 5 Install the replacement spring and damper unit Tighten the nuts to a torque of 42 64 ft lbs 60 88 N m 6 If the spring and damper that was removed was adjusted to meet the operating conditions of the vehicle adjust the new one to the same spring rate See Figure 4 25 7 Install the front wheel tightening the lu...

Page 140: ... the nut that holds the tie rod end to the hub assembly using a 19mm wrench Loosen the nut far enough that it can be turned easily with thumb and forefinger See Figure 4 27 6 Press the stud portion of the tie rod up using a two jaw puller or use a tie rod separator tool to break the taper fit between the tie rod end and the hub assembly See Figure 4 28 NOTE Tie rod separator tool aka pickle fork t...

Page 141: ...Install the wheel and tighten the lug nuts to a torque of 75 ft lbs 102 Nm 12 Check alignment and test drive the vehicle in a safe area before returning it to service Item ft lbs N m Tie rod end stud nuts 42 64 60 88 Lug nuts 65 75 88 102 Figure 4 29 9 16 wrench to hold tie rod Loosen tie rod end Upper Ball Joint Refer to the INSPECTION section of this chapter for information on when to replace ba...

Page 142: ...7 Position a two jaw puller to drive the ball joint downward out of the upper control arm See Figure 4 33 8 Clean inspect and lubricate the shouldered bore in the upper control arm before installing the new ball joint See Figure 4 34 9 Disconnect the bottom of the spring and damper unit from the upper control arm using a pair of 3 4 wrenches Loosen the nut and bolt that hold the top of the spring ...

Page 143: ...d by jack stands board and socket Figure 4 36 Position ball joint and socket carefully Socket supports ball joint by shoulder 11e Remove the socket when it meets the bot tom of the upper control arm 11f Continue driving the ball joint until it is fully seated See Figure 4 37 12 Alternatively if a hydraulic press is available the ball joint can be removed and installed on the press This requires up...

Page 144: ...tion of this chapter for information on when to replace control arm bushings 1 Separate the upper ball joint from the hub assembly as described in the Upper Ball Joint section of this chapter 2 Disconnect the bottom of the spring and damper unit from the upper control arm using a pair of 3 4 wrenches See Figure 4 39 2a Support the upper control arm 2b Loosen the nut and bolt that hold the top of t...

Page 145: ...to drive the replacement bushing in Press it until the outer steel sleeve of the bush ing is flush with the edge of the bore See Figure 4 42 5f Repeat the process for the second bush ing on the control arm NOTE Control arm bushing part numbers are not shown in the published Illustrated Parts List They can be ordered individually as part 741 04107 6 Fasten the control arm to the frame of the vehi c...

Page 146: ...hould be supported by the frame 2 Remove the front wheel using a 3 4 wrench 3 Loosen the nut that holds the lower ball joint to the front hub far enough that the locking feature nylon ring is clear of the threads Use a 19mm wrench See Figure 4 43 NOTE When loosening nuts with nylon locking rings that are installed on taper fit studs loosen the nut far enough to disengage the locking fea ture befor...

Page 147: ... arm to frame Washer front Figure 4 45 Lower ball joint Retaining ring 6 Carefully pry or drive a wedge between the lower control arm and the hub assembly to pull the ball joint down out of the hub See Figure 4 46 7 Swing the lower control arm free of the hub assembly as the two separate See Figure 4 47 8 Remove the nuts and bolts securing the lower control arm to the frame and remove the arm from...

Page 148: ... bore in the hub assembly 11 To install the new ball joint into the hub 11a Position the new ball joint under the hub with the metal shoulder of the ball joint supported by a seal driver or a length of tubing See Figure 4 49 11b Support the lower ball joint firmly and carefully align the body of the ball joint with the bore that it fits into in the hub assembly 11c Using a block of wood to prevent...

Page 149: ...5 Prop or jack up the front suspension to get the upper control arm roughly horizontal then tighten the nuts at the lower control arm frame pivot point to a torque of 32 36 ft lbs 43 49 N m NOTE This will lock the bushings near the static ride height so that they are not under a constant torsional load pre loaded 16 Install the wheel and tighten the lug nuts to a torque of 75 ft lbs 102 N m 17 Low...

Page 150: ...ervice intent If damage is evident on either bearing cup replace both cups and the race Bearing cups and races should always be replaced as a pair It stands to reason that if one bearing on a wheel is damaged the other will have suffered as well If there is reason to believe that the grease has been contaminated the bearings can be disas sembled cleaned inspected re packed and returned to service ...

Page 151: ...f PSI internal pressure it was not designed to handle tensile loads 6 Remove and discard the cotter pin that secures the axle nut See Figure 4 56 7 Remove the axle nut and the heavy flat washer behind it using a 32mm wrench Figure 4 55 Brake caliper removed Figure 4 56 Cotter pin 8 Affix an automotive hub puller to the axle and hub assembly See Figure 4 57 9 Use the hub puller to draw the hub and ...

Page 152: ...ibed in the Lower Ball Joint section of this chapter See Figure 4 61 13 Carefully slide the hub assembly off the axle and remove the from the vehicle 14 Remove the brake caliper bracket and shield using a 13mm wrench See Figure 4 62 15 Remove the retaining ring that holds the bearing assembly into the hub using a pair of internal snap ring pliers 16 Support the hub assembly in a hydraulic press so...

Page 153: ...igure 4 64 Figure 4 63 Figure 4 64 Wheel bearing assembly Hub cap Paper towel 19c Strike the hubcap on top of a work bench with sufficient force to cause the bearing cone to dislodge the seal See Figure 4 65 NOTE Keep track of which bearing was in which side of the cup While the bearing cones are identical they will wear into the cups with usage and the bearing cones should be kept running in thei...

Page 154: ...re the lower ball joint to the hub assembly with a retaining ring 23g Re connect the tie rod end to the hub Tighten the lock nut to a torque of 22 28 ft lbs 30 38 N m 23h Install the brake rotor on the hub and secure it with the heavy washer and cas tle nut 23i Tighten the axle nut to a torque of 150 165 ft lbs 203 224 N m and secure it with a new 5 32 x1 1 4 4x3 175cm cotter pin 23j Install the b...

Page 155: ...s using a 3 8 wrench 4d Remove the hairpin clips that hold the hood to the hinge pins slide the hood to the operator s left and lift it off of the vehi cle Figure 4 67 Tie rod end Two jaw puller 5 Remove the pad from the brake pedal using a 9 16 wrench NOTE Diesel models The radiator bracket fan and shroud cooling matrix assembly may get in the way of removing the hardware that holds the kick pane...

Page 156: ...ttle pedal using a 3 16 allen wrench and a 1 2 wrench See Figure 4 70 9c Remove the shoulder bolt that the throttle pedal pivots on using a 9 16 wrench and a 3 4 wrench See Figure 4 71 9d The throttle pedal can be removed as the kick panel comes out 10 Remove the drive shaft cover 10a Remove the 4 screws that secure the front driveshaft cover using a 1 2 wrench 10b Pry out the push in fasteners th...

Page 157: ...side similar Figure 4 74 fasteners Kick panel Dash support panel NOTE The far left bolt can be most easily loos ened from below the vehicle A socket and a long extension can be inserted behind the left side steering rack gaiter just inboard of the inner fender to reach the nut 11c Lift the kick panel out of the vehicle 12 Remove the clamp bolt that holds the bottom universal joint on the steering ...

Page 158: ...g gear box Install the nut on the bolt and tighten it to a torque of 32 36 ft lbs 43 49 N m 15e Re connect the tie rod ends and tighten the stud nuts to a torque of 22 28 ft lbs 30 38 N m 15f Reinstall the kick panel by reversing the steps used to remove it Position the throttle pedal as the kick panel is installed 15g Install the brake pedal pad 15h If the plastic bushings that support the thrott...

Page 159: ... may prevent the dash panel from being removed 3 Disconnect the negative cable from the battery located beneath the driver s seat to prevent any electrical connections from shorting out 4 Match mark and unplug the electrical connec tions to the dash panel See Figure 4 79 Key switch Hour meter Four wheel drive engagement switch 12 Volt power outlet Cub Cadet accessories that have been added Figure ...

Page 160: ...the driver s side hood and dash support bracket using a 3 8 wrench See Figure 4 84 10 Check the fit between the steering shaft and the bushings that support it in the steering wheel bracket If there is more than 040 1mm gap between the shaft and the I D of the bushing replace the bushings If the customer has complained about play in the steering shaft or if the steering shaft felt notice ably loos...

Page 161: ...er steering wheel shaft bushing 14 If the steering shaft is to be removed disconnect it from the splined input shaft of the steering gear box by removing the clamp bolt on the lower uni versal joint of the steering shaft Use a pair of 9 16 wrenches See Figure 4 88 NOTE The clamp bolt is easily reached through the opening that was created by removing the dash panel and the parcel bin that is molded...

Page 162: ...all the steering wheel bracket Tighten the nuts to a torque of 32 36 ft lbs 43 49 N m 16e Lubricate the part of the steering shaft that rides against the upper steering shaft bushing with grease 16f Install the upper bushing and secure it with an E clip 16g Install the hood and dash bracket 16h Install the dash panel 16i Install the steering wheel Tighten the patch bolt to a torque of 18 22 ft lbs...

Page 163: ...t Control arm bushing condition Hub bushing condition Wheel bearing condition Anti sway bar hardware NOTE In some instances toe and camber angle may be checked on the rear suspension Because they are not adjustable any variation in them is likely to be the result of damaged sus pension components 2 Rear suspension inspection Tire inflation See Figure 5 1 Check the air pressure in the tires They sh...

Page 164: ...n spring at the front of the vehicle can effect the ride height at the rear of the vehicle 5 Checking the rear wheel camber What is camber angle Camber angle is explained in Chapter 4 Front Suspension and Steering Rear wheel camber is adjustable through spring tension If camber is out of specification beyond this adjustment it is due to worn or damaged parts that should be replaced 5a Empty the lo...

Page 165: ...n the string and the two points should be equal Figure 5 4 Measure here 7 Inspecting spring and damper units See Figure 5 5 7a Make a visual inspection for _Broken coils _Leaking fluid from the damper _Bent shaft _Loose fasteners 7b Minor adjustments can be made to the rear spring rate and resultant ride height using a purpose built spanner to rotate the stepped lower spring perch 7c Ride height m...

Page 166: ...rear of the vehi cle as described in the LIFTING AND SUPPORTING section of the INTRO DUCTION chapter of this manual 9b Rock the wheel around a horizontal axis with greater force than was used to check the wheel bearings 9c Rock the wheel around a vertical axis with greater force than was used to check the wheel bearings 9d If there is motion have an assistant watch while the wheel is rocked so tha...

Page 167: ...trol arm moves easily the control arm bushings are worn Figure 5 9 Curved end of prybar Upper control arm bushing 11 Anti sway bar inspection See Figure 5 10 11a Check the nuts and bolts that hold the link ends for tightness 11b Check the spherical rod ends that are used as link ends for wear play 11c Check the anti sway bar mount and bush ings They should allow the bar to rotate freely but not mo...

Page 168: ...ches See Figure 5 12 5 Install the replacement spring and damper unit Tighten the nuts to a torque of 42 64 ft lbs 60 88 N m 6 If the spring and damper that was removed was adjusted to meet the operating conditions of the vehicle adjust the new one to the same spring rate See Figure 5 13 7 Install the rear wheel tightening the lug nuts to a torque of 75 ft lbs 102 Nm 8 Repeat the process on the se...

Page 169: ...he upper control arm using a 3 8 wrench Figure 5 14 Figure 5 15 4 Remove the bolts that fasten the control arm to the frame using a pair of 9 16 wrenches See Figure 5 16 NOTE Both bolts enter from the rear of the vehi cle Only the rearmost of the two bolts has a washer under its head 5 Lift the control arm out of the vehicle 6 To replace the bushings 6a Fixture the control arm on a suitable press ...

Page 170: ...int 8 Re connect the bottom of the spring and damper unit to the control arm tightening the nuts at both ends of the spring and damper unit to a torque of 42 64 ft lbs 60 88 N m 9 Prop the control arm so that it is roughly horizon tal then tighten the hub fasteners to a torque of 32 36 ft lbs 43 49 N m NOTE This will lock the bushings near the static ride height so that they are not under a consta...

Page 171: ... middle third of an hour glass The cup is held into the hub by a retaining ring at the outside The inside edge seats against a shoulder that is machined into the hub Bearing pre load is set by the torque of the axle nut Over tightening or under tightening will have an adverse effect on wheel bearing life Press in seals protect and retain the bearing cones in the cup Wheel bearing service intent If...

Page 172: ...oved the pads will come loose and the caliper will come free of the bracket on the hub assembly See Figure 5 22 CAUTION Support the caliper Do not allow it to hang on the flexible hydraulic line While the line will hold thousands of PSI internal pressure it was not designed to handle tensile loads 6 Remove and discard the cotter pin that secures the axle nut See Figure 5 23 Figure 5 20 C Clip Figu...

Page 173: ... assembly See Figure 5 25 Figure 5 24 Automotive hub puller Figure 5 25 leaving the hub in place The rotor and spacer can slide off 10 Remove the hub bolts using a pair of 9 16 wrenches See Figure 5 26 11 Carefully slide the hub assembly off the axle and remove the from the vehicle 12 Remove the retaining ring that holds the bearing assembly into the hub using a pair of internal snap ring pliers S...

Page 174: ... 29 16c Strike the hubcap on top of a work bench with sufficient force to cause the bearing cone to dislodge the seal See Figure 5 30 NOTE Keep track of which bearing was in which side of the cup While the bearing cones are identical they will wear into the cups with usage and the bearing cones should be kept running in their original cups 16d Remove the first bearing cone from the hub cap 16e Tur...

Page 175: ... 36 ft lbs 43 49 Nm Figure 5 31 Flat driver 2X4 Seal Bearing Race Bearing cone 20f Install the brake rotor on the hub and secure it with the heavy washer and cas tle nut 20g Tighten the axle nut to a torque of 150 165 ft lbs 203 224 N m and secure it with a new 5 32 x1 1 4 4x3 175cm cot ter pin 20h Install the brake pads and caliper Tighten the mounting pins to a torque of 22 26ft lbs 30 35 N m an...

Page 176: ...ng the above steps in reverse order 5 Test drive the vehicle in a safe area before returning it to service Sway bar and bushings removal 1 Remove the sway bar links as described above 2 Remove the sway bar bushing mounts using a pair of 1 2 wrenches See Figure 5 33 3 Remove the sway bar from the vehicle 4 Slide the old bushings off of the sway bar 5 Slide the new bushings onto the sway bar NOTE A ...

Page 177: ...d should be flushed and replaced every two years to prevent dam age to the master cylinder and the brake cali pers Treating brake fluid as a periodic maintenance item will dramatically extend the life of the brake calipers The master cylinder is mounted near the base of the structure that supports the steering column See Figure 6 1 Figure 6 1 Master cylinder reservoir Left front spring and damper ...

Page 178: ...pportioning valves BRAKE PUSH ROD ADJUSTMENT In the course of normal operation brake adjust ment should not be necessary If brake adjustment does become necessary check the system for wear damage and leaks 3 To make an adjustment loosen the brake cle vis jam nut using a 13mm wrench while holding the brake actuator rod with a 6mm wrench See Figure 6 4 4 Rotate the brake actuator rod in or out of th...

Page 179: ...d on the frame of the Cub Cadet utility vehicle line is relatively resilient to brake fluid surrounding surfaces may not be CAUTION If the brake fluid level is low identify and repair the leak before operating the vehicle 4 Remove the wheels using a 3 4 wrench NOTE Because the front and rear circuits are independent they can be bled independently It is most effective to start at the longer side of...

Page 180: ... is spongy find and repair the problem before operating the vehicle NOTE Though not shown in the Illustrated Parts List brake caliper bleed screws are available as service parts under the part number 759 04127 NOTE If it is suspected that air is trapped in the master cylinder it may be necessary to bleed the master cylinder 12 The procedure for bleeding at the master cylin der closely follows the ...

Page 181: ...he caliper bracket and may bow the rotor The giving and springing back of the metal parts will cause a soft pedal This situation is easily identified by visual inspection while an assistant works the brake pedal Air in the system Unless caused by leakage this condition will follow any service that requires the opening of the hydraulic system The sys tem should be bled after any such repair It blee...

Page 182: ...gish action in both directions The caliper s on the effected wheel s will apply slowly and release slowly Typical customer complaint if a front brake line is effected will be that the steering wheel pulls in one direction while the operator applies the brakes but pulls in the opposite direction when they accelerate away from a dead stop Master cylinder brake pedal not returning This would most lik...

Page 183: ...ll come free of the bracket on the hub See Figure 6 15 CAUTION Support the caliper Do not allow it to hang on the flexible hydraulic line While the line will hold thousands of P S I of internal pres sure it was not designed to handle tensile loads 6 Use a C clamp to drive the piston back into the caliper See Figure 6 16 Retracting the piston will make room for the additional thickness of the new p...

Page 184: ... slide pins and two retaining rings This will service a single wheel Two kits are required for an axle The same kit is used for front and rear wheels 10a If brake rotor has been removed install the brake rotor 10b Clean any grease oil or fingerprints from the brake rotor 10c Apply a very small amount of anti seize compound to the shoulders of the caliper mounting bolts slide pins 10d Position the ...

Page 185: ...30 35 Lug nuts 65 75 88 102 Component Repair Brake calipers 1 Remove the brake caliper as described previ ously in the AT WHEEL COMPONENTS section of this manual 2 Remove and inspect the slide bushings that go over the mounting pins See Figure 6 20 NOTE Clean any light corrosion with a Scotch Brite pad or similar product 3 Upon removal of the slide bushings remove and inspect the O rings Replace a...

Page 186: ...t thoroughly and continue with assembly If the bore is slightly worn or scored it may be lightly dressed with emery cloth If the bore is substantially worn or heavily dam aged replace the caliper NOTE Because the sealing surface is on the piston not the bore piston wall finish is more critical than bore wall finish 9 Clean all parts that are to be assembled 9a Initial cleaning may be done with Sto...

Page 187: ...ton O rings Caliper housing 13 Carefully insert the piston into the bore of the cylinder See Figure 6 26 14 Install the bleeder screws 15 Lubricate and install the o rings and slide bush ings NOTE On assembly lubricate the O D of slide bushings or the I D of the bore with a high tem perature synthetic grease that is meant for use on brake calipers Typical of these products is Versachem Part Number...

Page 188: ...ar front to rear and the rotor replacement method is identical 1 Remove the brake caliper as described in the Brake Pads section of this manual See Figure 6 28 2 Remove and discard the cotter pin that secures the axle nut See Figure 6 29 3 Remove the axle nut and the heavy flat washer behind it using a 32mm wrench 4 Affix an automotive hub puller to the axle and hub assembly See Figure 6 30 Figure...

Page 189: ...m 7c Apply a small amount of anti seize com pound to the hub splines before installa tion 7d Install the brake rotor hub washer and axle nut 7e Tighten the axle nut to a torque of 150 165 ft lbs 203 224 N m and secure with new 5 32 x 1 25 4mm x 32mm cotter pin 7f Install the brake caliper as described in the Brake Pads section of this manual NOTE The axle nut torque sets the pre load on the wheel ...

Page 190: ...nfirmed leak around the actuator rod that enters the end of the cylinder has failed and must be replaced before further use of the vehicle To Replace a Master Cylinder 1 Open and remove the hood for easy access to the master cylinder 1a Tilt the hood forward 1b Disconnect the wires from the headlights 1c Disconnect the hood check cables using a 3 8 wrench 1d Remove the hairpin clips that hold the ...

Page 191: ...aking fluid Figure 6 35 Left front fender Self tapping screws Nuts bolts Figure 6 36 Clevis pin Push rod Jam nut Yoke 11 Disconnect the brake lines using a 1 2 wrench See Figure 6 37 NOTE The front circuit is connected with a 90 degree elbow The rear circuit is connected with 45 degree elbow NOTE Inspect the copper washers sandwiching the fitting on the banjo bolt If the sealing face of any washer...

Page 192: ... of the master cylinder to the reservoir 14b Add brake fluid to the reservoir and pump the brake pedal until fluid flows from the bench bleeder tubes without bubbles 14c Carefully disconnect the bench bleeder tubes one at a time and reconnect the hydraulic lines 14d Tighten the banjo bolts to the specified torque 15 Bleed the entire brake hydraulic system starting at the furthest point of each cir...

Page 193: ... wrenches 4 With the bolt removed the pedal can be pulled out of the bracket that it mounts to See Figure 6 41 Figure 6 40 Brake yoke Brake pedal arm Clevis pin Figure 6 41 Bracket Bushing Brake pedal arm 5 Once the brake pedal is loose the bushings can be easily pried out and replaced 6 To remove the brake pedal arm from the vehicle See Figure 6 42 6a Unbolt the kick panel from the under dash sup...

Page 194: ...re 6 43 2 Drain and properly dispose of any residual fluid 3 Remove the 2 shouldered screws that secure the plastic reservoir See Figure 6 44 4 Remove the busings that seal the reservoir to the cylinder housing See Figure 6 45 5 Remove the push rod 5a Mark the threads on the push rod to main tain brake adjustment 5b If the jam nut was not loosened in the removal process hold the push rod with a 1 ...

Page 195: ...h rod retaining ring and retaining plate from the bore NOTE The rear piston assembly is lightly spring loaded It should extend slightly from the bore of the cylinder under its own spring pressure Figure 6 47 Dust seal Match mark for jam nut Figure 6 48 Retaining ring Push rod 6 Remove the rear piston and spring from the master cylinder bore See Figure 6 49 7 Remove the master cylinder from the vis...

Page 196: ...om the spring end of the rear piston 8d Remove the make up seal from the rear end of the rear piston See Figure 6 52 NOTE The open side lip of both seals faces the spring end of the rear piston The makeup seal is different from the power seal The makeup seal has a secondary lip near the closed rear side of the seal 9 Disassemble the front piston 9a Carefully pry the return spring and spring seat o...

Page 197: ...flex hone according to the manufacturers instructions 11 Clean all parts that are to be assembled 11a Initial cleaning may be done with Stod dard solvent 11b Final cleaning should be done using hot soapy water dish washing detergent is suitable a nylon brush and a nylon bore bush 11c Rinse and dry all parts thoroughly 12 Assemble the pistons using the new parts con tained in the kit installed as d...

Page 198: ...tion marked in the disassembly process 21 Lubricate and install the bushings that seal the reservoir to the master cylinder and secure the reservoir using the phillips head screws 22 Install the master cylinder in the vehicle as described the MASTER CYLINDER section of this chapter 22a Bleed the brakes as described in the BRAKE FLUID FLUSHING AND BLEED ING section of this chapter 22b Test the oper...

Page 199: ...e For engine specific information refer to the Owner s Manual and Service Manual published by Kohler that apply to the engine in this vehicle Follow all safety guidelines WARNINGs and CAUTIONs and service instructions in the Kohler Command Series CH18 26 and CH730 750 Owner s Manual 1 Access to routine maintenance points can be achieved by raising the cargo box releasing the Camloc fasteners that ...

Page 200: ... cover and lift them out of the housing See Figure 7 4 4d Look for evidence of dirt ingestion inside of the filter It will be most pronounced near the source of vacuum the carburetor throat See Figure 7 5 4e The filter can be knocked clean of dirt and may be re used if it comes clean Replace it if it appears dirty Do not wash the paper filter element Do not clean the paper filter element with com ...

Page 201: ...nthetic oil of 5W 20 or 5W 30 viscosity is suit able up to 40 deg f 4 deg c and may provide easier starting in low ambient temperatures Synthetic oil meeting the recommended specifi cations may be used in place of petroleum base oil New engines should be run on petroleum base oil for the first 50 hrs of normal use for proper piston ring seating 5h After changing the oil and filter test run the veh...

Page 202: ...ender off of the vehicle Replace the gas cap 6f The high tension lead and spark plug can be reached through an opening between thetopframememberandthefueltank See Figure 7 11 6g A deep 5 8 socket with a flex joint and and extension can be used to easily remove the spark plug 6h When installing spark plugs tighten them to a torque of 18 22 ft lb 24 5 30 N m NOTE Do not apply anti seize compound to ...

Page 203: ...emove the starter motor See Figure 7 14 8a Disconnect the negative battery terminal to prevent accidental arcing using an 8mm wrench 8b Disconnect the solenoid trigger wire from the male spade terminal on the solenoid 8c Draw back the insulator that covers the connecting post where the heavy gauge red cable attaches to the starter solenoid 8d Remove the nut that holds the heavy red cable to the st...

Page 204: ...gative battery terminal to pre vent accidental arcing using an 8mm wrench Remove the splash shield as described in sec tion 7 of this chapter Close the choke by pulling up the choke knob The knob is located left of the driver s seat Remove the air filter cover and clean the hous ing surrounding the air filter element Remove the wing nut that holds the air filter ele ment cover then lift off the el...

Page 205: ...e wires stator out put Violet wire Regulator rectifier out put Figure 7 20 Pull cooling fan shroud Remove fan 9 8 Remove the fan followed by the cooling shroud See Figure 7 21 9i Installation notes See Figure 7 22 Reverse removal process to assemble Carefully route and secure all wiring so it does not get pinched or chafed by other engine parts Position the shrouds correctly the cooling shroud fit...

Page 206: ...icle See Figure 7 24 Lift and support the cargo box Pry off the retainer that holds the lift assist cylin der to the cargo box Carefully lower the cargo box Use a length of 2X4 dimensional lumber to block the latch that normally secures the cargo box in the down position Remove the nuts and bolts that secure the cargo box to the frame using a pair of 9 16 wrenches With the help of an assistant or ...

Page 207: ... Figure 7 26 Figure 7 25 Engine transmission plate Figure 7 26 Engine transmission plate Engine spacer 9 Carefully disconnect the fuel line from the fuel pump inlet barb on the valve cover on the 1 cyl inder See Figure 7 27 Clamp the fuel line to prevent spillage Protect the inlet barb to keep contaminates out of the fuel system Cut the cable tie that holds the fuel line to the engine lift ear on ...

Page 208: ...nsfer case Withdraw the system up and rearward Figure 7 29 Exhaust manifold Figure 7 30 Cross member Muffler points mounting NOTE It is nearly as easy to separate the muf fler from the exhaust manifold but reassembly requires a fresh gasket It is simpler to remove the system without breaking the joint 14 Disconnect the heavy gauge red cable from the starter motor using a 13mm wrench See Figure 7 3...

Page 209: ...0mm wrench Figure 7 32 Engine is lifted and supported for final disconnection of wires Figure 7 33 Engine harness Vehicle harness 21 Remove the engine completely placing it on a strong workbench or stable work platform 22 Prior to engine installation check all the service points on the engine that are easily assessable while it is removed 23 Prior to engine installation check all of the ser vice p...

Page 210: ...ntains the correct amount of SAE 10W30 oil before starting it Test the operation of the vehicle and make any needed adjustments in a safe area before returning it to service Install with releasable thread locking compound such as Loctite 242 blue Install with permanent thread locking compound such as Loctite 262 red 25 Final assembly Install the front fender Install the front spring and damper uni...

Page 211: ...ay lead to mis fueling Gasoline in a diesel engine will cause immediate and severe engine damage Figure 7 35 Gasoline filler cap 3 Fuel line Gasoline powered utility vehicles made for the year 2006 are subject to CARB Tier III Emission regulations To meet these regulations they are equipped with Low Permeation SAE 30 R7 rated fuel line This fuel line can be identified by the green let tering on it...

Page 212: ...itting on top of the tank Clamp the line to prevent spillage or contamination Unplug the electrical connection to the fuel level sender 11 Remove the two screws that fasten the fuel tank hold down wire to the frame See Figure 7 39 12 Lift the fuel tank hold down wire up and pivot the front of the tank inward See Figure 7 40 13 Pull the fuel tank back and out to remove it 13 1 When installing the f...

Page 213: ... regulates the amount of vapor that escapes It also allows air to enter the fuel tank to take up room in the tank as the fuel is used The fitting consists of a plastic chamber that contains a regulating orifice Figure 7 41 Fuel pick up Bushing Figure 7 42 Vent fitting Bushing 16 When diagnosing a fuel starvation or flooding issue confirm that the vent is not blocked See Figure 7 43 17 Fuel level s...

Page 214: ...re 7 45 Slower idle speeds will result in poor idle quality reduced flow of cooling air and reduced oil flow Higher idle speeds will result in harsh gear selector action and possible internal damage to the transfer case 2 Top no load speed should be 3 850 RPM See Figure 7 46 Slower top no load speeds will result in dimin ished performance Higher top no load speeds will result in unsafe operating c...

Page 215: ...s confirm that no unsafe conditions will arise from running the engine Possible unsafe conditions include but are not limited to fire hazard exposure to hot or rotating parts asphyxiation and carbon monox ide poisoning 6 To adjust the engine speed remove the air filter cover but not the air filter NOTE Service the air filter if it is dirty A blocked air filter will effect idle speed NOTE The princ...

Page 216: ...ry lubri cants such as graphite or PTFE are preferred 11 Confirm that the cable is securely clamped in place at the engine end See Figure 7 50 If the cable is to be replaced match mark the location of the clamp using a paint marker Mark the new cable in the same location and use that mark to position the new cable Confirm that the cable as mounted has suffi cient travel to achieve the full range o...

Page 217: ...pedal travel stop bolt Throttle pedal Jam nut Throttle cable Pivot point eyelet Figure 7 53 Return spring hooks under cable clamp Cable clamp 16 Have an assistant hold the throttle pedal all the way down The throttle pedal arm stop against the head of the travel stop bolt See Figure 7 54 17 Pull the throttle cable housing to apply tension to the governor linkage Tighten the cable clamp with the go...

Page 218: ...r horn of the carbu retor See Figure 7 57 5 If the choke does not open and close completely with the operation of the knob the cable may be adjusted See Figure 7 58 Loosen the clamp that secures the choke cable to the governor bracket using a 5 16 wrench Shift the cable as necessary to achieve proper reaction of the choke plate to the control knob Tighten the clamp screw Re check the operation 6 I...

Page 219: ...r to reach the throttle linkage 4 Before adjusting the idle speed or governor con firm that the throttle cable operates properly 4a Look for physical damage 4b Operate the throttle and observe the movement 4c Blip the throttle pedal looking for consis tent engine response and return to idle 5 If the throttle cable linkage is suspect isolate the engine governor from the throttle cable to con firm t...

Page 220: ...re set check and adjust top no load speed See Figure 7a 5 Apply light force to the governor input arm bring ing it against the stop The engine should reach 3 600 RPM If adjustment is necessary use a pair of 6mm wrenches to adjust the length of the bolt that transfers movement from the governor input arm to the silver colored intermediate governor arm 10 Eliminate any linkage bind and play before a...

Page 221: ... 7 Pedal end cable adjustment Front of vehicle Throttle pedal arm Final Throttle Cable Adjustment 13 To get full travel adjust the pedal end of the cable so that the eyelet on the cable core just rests against the socket head cap screw that passes through it There should be 1 8 to 1 4 travel before tension is felt on the cable 14 After the cable is adjusted in its bracket check the adjustment of t...

Page 222: ...ernor input arm in contact with the stop screw See Figure 7a 11 18 Tighten the screw Start the engine and confirm that the engine idles at 1 200 RPM and reaches 3 850 RPM at wide open throttle 19 Test the operation of the vehicle in a safe area that is free of obstacles hazards or by standers before returning it to service If the cable and governor adjustment methods are unsuccessful engine perfor...

Page 223: ...nts on the engine as it is positioned in the vehicle For engine specific information refer to the Opera tion and Maintenance Manual published by Caterpillar or get the vehicle to a Caterpillar dealer Follow all safety guidelines WARNINGs and CAUTIONs and service instructions that pertain to Caterpillar Engine Model C0 7 and the Cub Cadet Operator s Manual 1 Access to most routine maintenance point...

Page 224: ...es will be serviced according to the terms Industrial Service Dealer Program ISD Under this agreement ISD dealers will be able to provide Non intrusive service using genuine Caterpillar parts supplied through Caterpillar s distribution system Caterpillar Warranty claims will be administered through the partnering Caterpillar dealer Intrusive service will be done by the partnering Caterpillar deale...

Page 225: ...down stream of the air fil ter it is best left un disturbed 2 To reach the air filter 2a Turn off the engine Removing the air filter with the engine running will allow dirt to enter the engine 2b Slide the driver s seat all the way back tilt it forward and remove the parcel bin from beneath the seat See Figure 8 6 2c Clean the area surrounding the air filter Figure 8 6 Parcel bin 2d Lift the lock ...

Page 226: ...ling surface Because of the three dimensional nature of the filter media visual inspection of the surface does not provide an accurate indication of the media condition The Cub Cadet utility vehicle is not equipped with an air filter service indicator In summary If it is not necessary to remove the filter it is best left alone until the replacement interval is reached or restriction causes loss of...

Page 227: ...40c to 10c SAE 0W 30 40f to 86f 40c to 30c SAE 0W 40 40f to 104f 40c to 40c SAE 5W 30 22f to 86f 30c to 30c SAE 5W 40 22f to 122f 30 to 50c SAE 10W 30 0f to 104f 18c to 40c SAE 10W 40 0f to 122f 18c to 50c SAE 15W 40 15f to 122f 9 5c to 50c 6 To change the engine oil 6a Warm up the engine Not only will the oil flow out of the engine more easily but more contaminants will be suspended in the oil th...

Page 228: ...l filter is roughly 2 85 Qts 2 7L 6l Disconnect the fuel solenoid by unplugging the connection from the engine wiring har ness See Figure 8 14 6m Crank the starter motor until the OIL light on the instrument cluster goes out Do not exceed 30 seconds of cranking If more than one interval is needed give the starter motor two minutes to cool down before repeat cranking 6n Re connect the fuel solenoid...

Page 229: ... CAUTION Diesel fuel is toxic Dispose of any waste fuel in a safe and environmentally respon sible manner Contact your local EPA office for proper disposal methods and recycling center locations CAUTION Diesel fuel injection systems operate at pressures that are high enough to penetrate the skin If any high pressure leak is suspected direct exposure to the fuel system when it is in operation is ex...

Page 230: ...rce of potential ignition CAUTION Diesel fuel is toxic Dispose of any waste fuel in a safe and environmentally respon sible manner Contact your local EPA office for proper disposal methods and recycling center locations CAUTION Diesel fuel injection systems operate at pressures that are high enough to penetrate the skin If any high pressure leak is suspected direct exposure to the fuel system when...

Page 231: ...Install the replacement filter cartridge by pushing it straight onto the filter housing with the ears aligned to fit the notches in the housing The unlock icons on the filter cartridge and filter housing should be aligned or nearly aligned to show the ori entation of the ears when the filter can be pushed up See Figure 8 19 8j Rotate the filter cartridge 90 degrees 1 4 turn clockwise as seen from ...

Page 232: ...ng NOTE The fuel system will effectively self prime Once the engine is started there is no reason to open the bleed screw Other maintenance items 1 The crankcase breather valve is mounted on top of the valve cover intake manifold assembly It should be serviced every 2 000 hrs of use 1a Clean thoroughly around the breather assembly NOTE The breather is at the junction of the lubrication system and ...

Page 233: ...and may damage engine components 3 Alternator and water pump belt The belt should be inspected and adjusted if necessary at 250 hr intervals The belt should be replaced at 1 000 hr intervals or after four years of use Following belt replacement the belt should be inspected and adjusted after a jog start or 3 min utes of operation then again after 5 hrs or one day of use CAUTION Do not work near th...

Page 234: ...j Tighten the tension adjusting bolt then the pivot bolt to a torque of 13 ft lbs 18 N m then re check belt tension 4 Alternator removal Test the alternator as described in the Electrical Chapter of this manual before removing it Contact the partnering Caterpillar dealer before removing the alternator from the vehicle 4a Tilt the driver s seat forward and release the Camloc fasteners to remove the...

Page 235: ...ouldered spacer that fits between the alternator and the engine block See Figure 8 30 4j Pull the alternator out through the rear fender opening 4k Reverse the removal procedure to install the alternator 4l Set belt tension and tighten fasteners as described in the alternator and water pump belt section of this chapter 4m Re connect the negative battery terminal test run the vehicle and check the ...

Page 236: ...block using a 14mm wrench See Figure 8 32 5f Again working from the front of the engine loosen the upper screw that holds the starter to the engine 5g Remove both screws and withdraw the starter motor through the right rear fender See Figure 8 33 5h While the starter is out the ring gear will be visible Examine the teeth particularly if the starter was removed because of an engagement problem See ...

Page 237: ... shield 6 Flywheel NOTE Contact the partnering Caterpillar dealer before removing the flywheel from the engine 6a Remove the driving clutch as described in the CVT and Transfer Case chapter See Figure 8 35 Figure 8 35 Driving clutch element Puller tool 6b Remove the tapered shaft adaptor using a 16mm wrench See Figure 8 36 NOTE Caterpillar gives no indication whether their rotating assemblies are ...

Page 238: ...installation notes The flywheel is held to the crankshaft by bolts Bolts work in compression There is no dowel and it is better not to load bolts in shear There is enough friction between the drive boss on the end of the crankshaft and the recess that it fits into on the flywheel to transfer drive force This friction is maintained by the torque of the bolts Torque is critical It is also critical t...

Page 239: ...mplete the reassembly by reversing the removal process 7 Exhaust system CAUTION Do not work near the exhaust sys tem after the vehicle has been run until the exhaust system has cooled Figure 8 41 M10 1 25 stud aids in flywheel alignment 7a The exhaust system is covered by a series of heat shields See Figure 8 42 The top exhaust heat shield covers the exhaust system from the manifold to the muffler...

Page 240: ... be removed for cleaning or replacement using a 1 4 wrench See Figure 8 46 7c There are essentially two things that can go wrong with an exhaust system leakage or blockage Leakage whether it is internal baffles or exter nal will result in a louder exhaust note If the exhaust gets louder identify and correct the source of the leak External leaks in particular can over heat or burn other components ...

Page 241: ...efore remov ing the radiator cap or loosening any fittings The coolant becomes heated and pressurized in normal operation CAUTION Always loosen the radiator cap slowly to release any residual pressure before removing the cap or loosening any fittings in the cooling system CAUTION Coolant is toxic Clean up spilled coolant immediately Dispose of all waste cool ant in an environmentally responsible m...

Page 242: ...oling matrix 2d Metal coolant pipes connect the engine to the radiator See Figure 8 50 2e A thermostat on the engine regulates the flow of coolant between the engine and the radiator 2f A belt driven water pump circulates cool ant between the engine and the radiator when the thermostat is open See Figure 8 51 2g Because the elevation of the system is low in the middle coolant pipes under the passe...

Page 243: ...coolant travels forward and the pipes shift from a vertical orientation upper and lower to a horizontal side by side orientation The upper pipe becomes the inner pipe See Figure 8 53 Figure 8 52 Thermostat housing Vent plug Figure 8 53 To radiator Return The coolant enters the top rear of the radiator on the left side See Figure 8 54 The coolant exits the radiator at the bottom front on the right ...

Page 244: ...on The fan switch is mounted on the bottom front edge of the radiator next to the return hose con nection See Figure 8 58 NOTE In this location the fan switch monitors the temperature of the coolant as it exits the radiator If the exit temperature of the coolant is not low enough the fan turns on to pass more air through the radiator A 1 U S Qt 95 L reservoir is mounted next to the radiator The pr...

Page 245: ... applications NOTE Coolant specifications are usually listed on the package label or available on the coolant manufacturer s web site If not specifically listed do not assume it meets the specification NOTE Distilled or deionized water is recom mended for coolant solution if local tap water is high in mineral content NOTE SCA Supplemental Coolant System Additive should not be necessary given the r...

Page 246: ...rvice 4 Draining and filling coolant NOTE Before draining the coolant pressure test the cooling system and inspect it for any signs of leakage Most cooling system repairs require at least a partial draining of the system It makes sense to do any necessary repairs in conjunction with coolant replacement 4a Remove the splash shield as described in the water pump and alternator belt section of this m...

Page 247: ... was designed to hold so it should only be done if there are substantial openings in the system CAUTION Wear eye protection when using compressed air to force water out of the system CAUTION Clean up any spilled coolant immedi ately and dispose of it in a safe legal and envi ronmentally responsible manner 4l Apply thread sealant to the block drain plug and reinstall it immediately after draining i...

Page 248: ...ating 4v Run the engine until the thermostat has cycled open and closed two times using a non contact thermometer to monitor the temperature of the engine and cooling system 4w Allow the engine and cooling system to cool 4x Check the coolant level at the radiator filler neck Top up if necessary before return ing the vehicle to service See Figure 8 66 NOTE In service it should not be necessary for ...

Page 249: ...and a dust mask at minimum when using compressed air to clean the radiator CAUTION Do not get the blow gun close enough to the radiator core to dislodge or dam age the fins If the fins show any signs of dam age or distortion from the cleaning process stop cleaning immediately 5f Heavier mud can be cleared using a water hose Use line head pressure only Do not pressure wash the radiator See Figure 8...

Page 250: ...n something is successfully dis solved in a liquid it is said to be held in suspen sion solids or solution liquids Water and other liquids have the capacity to hold a certain amount of solids in suspension The amount varies with the liquid and the temperature When that amount is exceeded the solids fall out of suspension 6b In most cases with aluminum radiators if there is enough corrosion to effe...

Page 251: ...e 8 71 Figure 8 71 Thermostat housing Exhaust manifold The thermostat is referred to in Caterpillar text as a water temperature regulator For the pur poses of this text the two terms are used inter changeably Caterpillar recommends replacing the thermo stat every 3 000 hrs of operation or at 2 year intervals Caterpillar considers thermostat replacement to be intrusive repair Contact your partnerin...

Page 252: ...her problem belt water pump obstruction If the block temperature rises to nearly 160 deg f 71deg c and the to radiator pipe remains cool until that point then suddenly rises to the same temperature the thermostat is operating correctly NOTE The thermostat opens at 167 deg f 75 deg c but the insulating properties of the metal reduce the surface reading There is a weep hole in the body of the thermo...

Page 253: ...oolant circulation there may be an internal problem with the water pump impeller or thermostat If this is the case contact the partnering Caterpillar dealer Figure 8 75 Non contact thermometer Point measurement 11 Cooling system component removal cooling matrix NOTE Generally the cooling matrix is most easily removed as a complete unit then disas sembled on the bench The cooling fan may be easily ...

Page 254: ... 11g Remove the radiator cap to speed draining NOTE With the coolant drained from only the radiator it can be removed with minimal fluid loss and minimal drainage 11h Disconnect the front radiator hose from the lower front radiator tank using a 5 16 driver 11i Cap or tape the hose to prevent contami nation and minimize spillage 11j Pull the over flow tube connecting the reservoir to the fitting on...

Page 255: ...hose 11m Loosen the hose clamp disconnect the hose and remove the cooling matrix to a clear workbench See Figure 8 82 11n Any further disassembly can be done eas ily on the bench NOTE If the radiator is to be replaced it is nec essary to drill out the pop rivets that fasten the air baffle to the radiator Replace them with locally purchased 3 16 X 450 steel pop rivets 11o Install the radiator by re...

Page 256: ...ive post on the battery 13c Remove the splash shield and drain the coolant from the return pipe as described in the Draining and Filling section of this chapter See Figure 8 84 13d From underneath the front of the vehicle match mark the to radiator pipe and hose inboard pipe 13e Place a catch pan under the match marked joint and disconnect the pipe from the hose Loosen the hose clamp using a 5 16 ...

Page 257: ...bracket To radiator pipe Pipe clamp mounting screw Return pipe hose Figure 8 88 Cut here to remove 13m Match mark the return pipe for alignment in such a way that the pieces can be dis tinguished from the pieces of the to radia tor pipe 13n Use a compact tubing cutter ratcheting tubing cutter or a hacksaw to cut the to return pipe at this point See Figure 8 89 13o Remove the rear half of the retur...

Page 258: ...es 13t Install the front length of the return pipe then install the front length of the to radia tor pipe NOTE The return pipe needs to go in first because it fits between the frame channel and the to radiator pipe NOTE Insert the back end of the front lengths first then draw the front lengths toward the front of the vehicle for final positioning 13u Secure the pipes to the frame using the mountin...

Page 259: ...s non vented See Figure 8 93 CAUTION The fuel caps for gasoline and diesel versions of this vehicle use the same neck size and thread The fuel caps are distinctly labeled Though they are mechanically interchangeable it is strongly recommended not to switch fuel caps between the gas and diesel engines This may lead to mis fueling Figure 8 93 Diesel Fuel Only fuel cap Diesel engine 3 Fuel line 3a Th...

Page 260: ...r de energized See Figure 8 97 7 To reach the fuel tank for most service require ments remove the rear fender and splash shield 7a Tilt up the load bed 7b Remove the 3 screws that hold the fender to the splash shield using a 5 16 wrench See Figure 8 98 7c Remove the remaining fasteners that hold the fender to the vehicle See Figure 8 99 Remove the two screws that hold the front edge of the fender ...

Page 261: ... 8a The fuel level sending unit forward of the others 8b The fuel pick up for the engine brass fit ting is mounted out board 8c The fuel return from the injector pump is mounted furthest in board 8d The fuel tank vent with no line connected to it plastic fitting is mounted between the fuel pick up and the fuel return 9 To remove the fuel tank See Figure 8 102 Disconnect the fuel supply line from t...

Page 262: ...talling the fuel tank reverse the instruc tions for fuel tank removal 15 Fuel pick up fitting See Figure 8 106 The fitting consists of a brass 90 degree elbow and an plastic tube The tube reaches to near the bottom of the fuel tank and is shrunk onto the fitting When diagnosing a fuel starvation issue do not over look the possibility of an air leak between the elbow and the pick up tube For instal...

Page 263: ... or flooding issue confirm that the vent is not blocked See Figure 8 108 Figure 8 107 Figure 8 108 No pressure No vacuum Vent good 18 Fuel level sender See Figure 8 109 As the fuel level goes down the float lowers causing the switch to make contact and illumi nating the low fuel warning light For installation install the bushing first lubricate the fitting with diesel fuel and install it in the bu...

Page 264: ...stalline solid structure The pour point is a measure of viscos ity These factors make 1 diesel fuel more suit able to cold weather operation When burned 1 diesel fuel produces less energy per unit of volume than does 2 diesel fuel A vehicle that is fueled in one climate and trans ported to a different climate may experience fuel related starting or performance issues SVO bio diesel and other organ...

Page 265: ...stop screw stop screw High speed Idle speed NOTE The governor feature is built into the fuel injector pump If the engine over speeds fails to reach 3 600 RPM top no load speed or fails to idle at the correct speed and the throttle cable is moving the governor arm through it s full range of motion then there is a performance issue with the engine or an internal governor injector pump problem Unless...

Page 266: ...ravel adjust the pedal end of the cable so that the eyelet on the cable core just rests against the socket head cap screw that passes through it There should be 1 8 to 1 4 travel before tension is felt on the cable 11 After the cable is adjusted check the travel stop bolt under the pedal See Figure 8 117 The travel stop should be set to allow full speed operation without over travel the pedal stop...

Page 267: ... check the operation Figure 8 119 Throttle arm against high speed stop screw coincides with end of throttle pedal travel does not bow cable bracket High speed stop screw Cable bracket ENGINE PERFORMANCE ISSUES 1 If the over temp light on the panel or oil pres sure light on the instrument cluster come on and the cause cannot be found or eliminated using non intrusive means contact the partner ing C...

Page 268: ...cause serious burns 1 Remove the cargo box from the vehicle See Figure 8 120 Lift and support the cargo box Pry off the retainer that holds the lift assist cylin der to the cargo box Carefully lower the cargo box Use a length of 2X4 dimensional lumber to block the latch that normally secures the cargo box in the down position Remove the nuts and bolts that secure the cargo box to the frame using a...

Page 269: ... cable ties that hold the cable to the frame and the fuel injector rail 5d Draw the cable forward and out of the engine bay Figure 8 121 Figure 8 122 Rear differential C V joint Loosen bolts Cable bracket 6 Drain the coolant from the engine and coolant pipes as describe in the Draining and Filling Coolant section of this chapter See Figure 8 123 7 Disconnect the throttle cable from the engine See ...

Page 270: ...ield using a pair of 1 2 wrenches See Figure 8 128 NOTE The following instructions are written on the assumption that the engine being removed will be reinstalled The procedures include block ing off all exposed ports on the engine to prevent contamination or damage If the engine is worn or damaged beyond feasible repair it is not nec essary to lock off the ports It is still a good idea to block o...

Page 271: ...e Figure 8 130 Disconnect and remove coolant hoses Remove the hoses and rigid pipe that connect the thermostat housing to the to radiator pipe Remove the hose that connects the return pipe to the water pump Inspect the hoses and clamps If the hoses are cracking softening or swelling replace them with new ones and thoroughly inspect the hoses that connect the coolant pipes to the radiator If the en...

Page 272: ...ter assembly is easily removed The technician may do so for easier access 18 Remove the 3 screws that hold the tapered shaft adaptor to the flywheel using a 16mm wrench and remove the adaptor 19 Remove the 5 sets of nut and bolts that hold the steel engine to transmission plate to the engine using a pair of 1 2 wrenches See Figure 8 135 19a Remove the 4 screws that hold the engine to transmission ...

Page 273: ...engine and transfer case tray using a 16mm wrench See Figure 8 138 Figure 8 137 Drain plug Engine support bolts Figure 8 138 Loosen screws 22d Remove all but 2 of the screws The screws left in place should be at opposite ends of the 2 rows of screws See Figure 8 139 22e Attach a lifting apparatus and apply enough lifting force to relieve the shear load from the remaining 2 screws Remove the screws...

Page 274: ...may be nearing the end of their service life If the reason for the engine failure was external to the engine identify and correct the problem Inspect the wiring harness and connections 25 Reverse the removal steps to install the engine Connect the ground wire and cable to the engine before lowering it into position Connect both neutral safety switches and the engine oil pressure sender while the e...

Page 275: ...be to replace or repair the tray itself To remove the tray first remove the engine as described in the ENGINE REMOVAL section of this chapter and remove the transfer case as described in the CVT and TRANSFER CASE chapter of this manual 1 Checking the mounts 1a Lift up on the engine tray using a jack or pry bar to check the condition of the rub ber mounts See Figure 8 142 The four corner mounts are...

Page 276: ... 143 2b Remove the center bolt from both mounts on the side that is to be replaced See Figure 8 144 2c Lift up the engine and transfer case tray far enough to allow easy access to the fasteners that hold the mount to the frame See Figure 8 145 2d Unbolt the mount from the frame using a pair of 1 2 wrenches 2e Slip the mount out from between the tray and the frame See Figure 8 146 2f Reverse the re...

Page 277: ...ray forward far enough for the boss on the rubber bushing to clear the bore that it seats into on the rear lip of the tray See Figure 8 148 Figure 8 147 Figure 8 148 Pry tray forward 3e Reverse the removal procedure to install the mount Use caution not to pinch the brake line when working on the driver s side mounts If working with the engine removed install the center bolt from the rear with the ...

Page 278: ...Chapter 8 Caterpillar Engine and Related Systems 274 ...

Page 279: ...inal CAUTION Unless performing tests that require the electrical system to be in operation discon nect the negative cable from the battery before doing any work to the electrical system of the vehicle CAUTION Refer to Section 5 of the Operator s Manual and Section 3 of this chapter for normal maintenance procedures and precautions that relate to the battery COMPONENTS 1 Fuse and Relay Center Kohle...

Page 280: ...fuse and relay holders from the fuse and relay center Insert a pair of small screwdrivers into the cavi ties above the top corner of the holder and pry up on the release tabs See Figure 9 3 Pry down on the bottom release tab of tabs in similar fashion and remove the fuse and relay holder Item Place Rating Accessory Relay R1 20 35A 14V Start Relay R2 20 35A 14V Park Buzzer Relay R3 20 35A 14V Fan r...

Page 281: ...nused F3 N A Front Accessory 2 F4 30A ATM Unused F5 N A Unused F6 N A 4 Additional Fuses and Relays at Relay Center Position Two Location Open the hood to reach the fuse and relay center It is mounted on the firewall imme diately forward of the steering column There are three positions in the relay center The fuses and relays for rear mounted optional equipment if present occupy position two the c...

Page 282: ...lug relay con trols power to the bus bar that energizes the glow plugs See Figure 9 6 6 Addition Relay for Light Bar Location Open the hood to reach the fuse and relay center It is mounted on the firewall imme diately forward of the steering column If equipped with a light bar the relay will be mounted beneath position two of the relay cen ter Wire Function White Black trace Fused 5A constant hot ...

Page 283: ...ad 1 0Ω or O L when the relay is energized Figure 9 7 Spade 3 Common Spade 4 N C Spade 2 Windings Spade 1 Windings Spade 5 N O O O O O O O 3 4 5 1 2 Inset Circuit diagram of relay printed on the side of some relays Terminal 5 is the Normally Open terminal It connects to terminal 3 when the relay is ener gized When 3 4 are connected 3 5 are dis connected and vice versa An Ohm meter should show zero...

Page 284: ...ect the harness that leads to the neutral safety switches Connect a DVOM or continuity light to the pair of terminals on the disconnected harness When the transfer case is in neutral there should be continuity 0 0 Ω between the two wires in the terminal If there is no continuity through the circuit when the transfer case is in neutral check the switches individually to identify the one with con ta...

Page 285: ...om of the transfer case Figure 9 10 Lower switch F and H Upper switch L range Ohm test here 9c The brake switch is not tied to the starter circuit It illuminates an LED on the hour meter when the brake is engaged and sounds a warning beeper if the vehicle is put in gear while the brake is engaged See Figure 9 11 The brake switch is located directly under the parking brake handle and it is easily a...

Page 286: ...rd side of the cooling fan shroud See Figure 9 14 Refer to the KOHLER SERVICE ACCESS AND FUEL SYSTEM chapter of this manual for spe cific removal instructions Refer to the MAJOR CIRCUITS section of this chapter to test the charging system 12 The Fuel Shut off Solenoid for the Kohler engine is attached to the carburetor Refer to the KOHLER SERVICE ACCESS AND FUEL SYSTEM chapter of this manual for s...

Page 287: ...noid trigger wire Yellow Green Oil pressure sender Red with black trace White Magneto ground Orange Red wire and pur ple wire Current to charge bat tery and power acces sories Figure 9 16 15 The Alternator Regulator Rectifier of the Caterpillar engine is mounted at the rear of the outboard side of the engine See Figure 9 17 Refer to the Caterpillar Engine and Related sys tems Chapter of this manua...

Page 288: ...el shut off solenoid When the fuel pump is in operation it makes an audible clattering that can be identified with the key on engine off A slight vibration or pulsation is noticeable to the touch on the pump and fuel line when the pump is in operation If the fuel system is dry the pump will be espe cially loud until it has drawn a prime The Kohler engine uses a mechanical fuel pump Wire in main ha...

Page 289: ...ion Fuel shut off solenoid pump Injector 19 The 4x4 Activation switch contains a simple open or closed set of contacts The switch is easily removed from the dash panel by unplug ging the electrical connector and squeezing the tabs on the narrow sides of the switch See Figure 9 21 The switch receives power from the same orange wire circuit as the fuel shut off solenoid and fuel pump in diesel appli...

Page 290: ...hat faces the operator Because the dash is covered with an overlay it is necessary to remove the electrical devices from one side of the dash and peel back the overlay in order to remove the hour meter See Figure 9 23 A variety of sensors feed information to the hour meter Internal circuitry reads this information and provides the operator with appropriate sig nals The function of each wire connec...

Page 291: ... not provided informa tion about their pressure switches Figure 9 25 Oil pressure sender Figure 9 26 Oil pressure sender 21b The Fuel light is Illuminated when a float in the fuel tank sinks far enough to close a set of contacts See Figure 9 27 The contacts complete a path to ground send ing a signal to the hour meter to illuminate the fuel LED The purple wire leads to the hour meter the green wir...

Page 292: ... hours of operation 21e The Brake light illuminates when the parking brake is applied and the key switchisinanypositionotherthanSTOP Operation of the brake switch is described in the SAFETY SWITCHES section of this chapter 21f The Glow Plug light diesel only is the yellow lamp between the key switch and the warning light cluster hour meter See Figure 9 30 The glow plug light receives power from a ...

Page 293: ...reen wire to ground Figure 9 33 Continuity Red probe to spade terminal marked red Red mark Flat No continuity Red probe to spade terminal near flat side of housing 23 The Cooling fan diesel only is mounted under the hood atop the radiator It is wired to blow cool air down through the radiator core See Figure 9 34 NOTE Blowing cool air down from the top gets the cool air to the hottest top part of ...

Page 294: ...9 36 Unplug the wires from the lamp to remove them Leave the lamps in place if the hood is being removed for service access The lamps only go into the housing in one orien tation and they are removed with a 45 degree counter clockwise twist The lamps are powered directly from the L termi nal on the key switch through the pair of yellow wires parallel circuits The green wires from each lamp are par...

Page 295: ...he Accessory Har ness Plug are described in the table below Wire Function Red Bed lift Yellow Bed lift Orange Power supply when key is in any position other than STOP Black Rear accessory Purple Rear accessory Figure 9 38 Wing nut 12V Power outlet The accessory harness plug itself is located near the fuse and relay center It is the connection point for the accessory harness See Figure 9 39 The bed...

Page 296: ... loosened and removed using a 10mm wrench The battery part number shown in the first year Illustrated Parts List is for the wet battery use on the production The dry battery used for service is part num ber 725 04514 This is a 12 volt battery having a capacity of 540 cold cranking amps at zero deg f 18 deg c CAUTION When disconnecting or removing the battery disconnect the ground cable first When ...

Page 297: ...ignals to a processor These input signals are processed by a control module that produces outputs Outputs can include power to run an electric PTO clutch a trigger signal to a starter solenoid or the grounding of a magneto to turn off an engine if an unsafe condition exists Most electronic devices are quite dependable but they are vulnerable to things that simple electrical devices are not bothere...

Page 298: ...or short The capital letter I is used to represent Amps 3 Ohms Resistance Resistance is the opposition to current flow It is a restriction that slows down the flow of current Resistance is measured in Ohm s The greek letter omega Ω or the letter R for Resistance is used to represent Ohm s Resistance creates heat A circuit with too much electrical load or too much resistance for the load placed on ...

Page 299: ...hoff s voltage law deals with voltage drops A voltage drop is the amount of voltage used up or dropped by resistance in a circuit Ohm s law states that V IxR every component in a circuit has resistance even the wires To push current through resistance it takes volt age Kirchhoff s voltage law states that the sum of all the voltage drops equals the source volt age As an example imagine a circuit th...

Page 300: ...y point on the frame should be the same as the negative post of the battery Electrically unless there is a bad connection between the battery and the frame or between the frame and the component or cable that is assumed to be grounded to it 7d Most circuits have additional components like switches and fuses Types of circuits There are three ways a circuit can be wired Series Parallel Series parall...

Page 301: ...e caused by loose or cor roded connections or connections that are insu lated by grease paint or coatings Fasteners finished in oil phosphate or black oxide are bad conductors Use bright fasteners zinc coated Resistance can be problem on the ground side as well as the hot side of a system remember that electricity must complete a loop circuit back the battery post Any resistance in that loop will ...

Page 302: ...thout breaking the circuit Testing amperage beyond the capacity of the meter can burn out an internal fuse in some meters The fuses can be expensive Resistance Set the meter for the Ω scale Isolate the part of the circuit to be tested discon nect it from the source of power Ohms are read on a scale of 0 to 1 with 0 indicating no resistance and 1 indicating infinite resistance Most auto ranging met...

Page 303: ...s an LED to indicate the presence of power Figure 9 51 Hi impedance test light Incandescent GOOD test light CAUTION Some high impedance test lights are capable of indicating whether the current being sampled is AC or DC Self powered continuity lights Continuity lights can indicate whether a circuit is complete or not but they give no indication of resistance They are handy for finding point break ...

Page 304: ...orks on Kohler regulator rectifiers and the company claims it works on similar systems from other companies See Figure 9 55 Instructions are included with the Kohler tool TT480 A Testing the charging system Quick and dirty test check voltage across the battery posts using a DVOM set to read D C voltage with the engine turned off It will read battery voltage typically around 12 V Start the engine a...

Page 305: ...PM 1d Read the voltage on the meter 1e If the voltage is substantially low try the other white wire Figure 9 56 Regulator rectifier probe to white wire Raw stator out put 3 600 RPM 2 If raw out put of the running Kohler alternator is less than 28 volts check the stator 2a With the engine stopped unplug the stator lead from the voltage regulator rectifier 2b Check the stator for resistance across t...

Page 306: ...the amperage on the meter See Figure 9 59 NOTE Output varies with load A fixed load battery tester can be used to apply enough load to test the charging system out put 3f With the engine off connect Kohler tool 25 7651 20 to the regulator rectifier The two black leads go to the terminals normally connected to purple stator leads The red lead goes to the center terminal B The ground clip goes to gr...

Page 307: ...allow an open flame or heat source near the battery Charge batteries in an open area Wear eye protection and gloves when handling batteries Do not allow direct metal contact across the posts This will produce extreme heat that may cause direct burns or ignite flammable gas CAUTION California Proposition 65 warning Battery posts terminals and related accessories contain lead and lead compounds Thes...

Page 308: ...nt battery at a rate higher than 2 amps Damage to the battery will result CAUTION Never attempt to charge or jump a frozen battery 3c Charge the battery until it is fully charged Most battery chargers have an amp gauge to show the charging rate When the gauge is at zero stop charging the battery 4 Checking battery condition There are three things to do when testing a battery Visual inspection Elec...

Page 309: ...ways to check a battery Electrolyte test using a Specific Gravity tester to compare the density of the electrolyte in a fully charged battery to the density of water water 1 0 s g Electrolyte test using a Refractometer to check the density of the electrolyte by measuring the degree to which light waves bend when passing through the electrolyte Load test that checks the out put of the battery after...

Page 310: ...tery NOTE Because they have a fixed load value they do not give most batteries a reliable and safe load test Most fixed load testers have a load that is more than 50 of the rated CCA of riding mower batteries This makes them inap propriate to use on smaller pieces of outdoor power equipment 2a Disconnect the battery cables ground first 2b Measure the temperature of the electrolyte in the middle ce...

Page 311: ... battery will discharge while sitting unused To test for a battery that is leaking voltage 4a Confirm that operator technique is not cre ating a situation that cases a draw As an example if a homeowner habitually turns their equipment off using a safety switch perhaps vacating the seat with the key switch still ON that may leave a relay or fuel shut off solenoid energized 4b Disconnect and charge ...

Page 312: ...indicator lamps as a guide to direct the search As an example when diagnosing a no crank condition on a lawn tractor with a PTO safety switch if the PTO light is lit on the hour meter but the technician has visually verified that the PTO clutch is not engaged the PTO circuit would be a reasonable place to check for prob lems Check the battery A valid diagnosis of many systems cannot be made withou...

Page 313: ...tor until the other end of the circuit is reached or the fault is found Figure 9 69 Voltage Drop Test To review Ohm s law states that it takes voltage to push current through a resistance Kirchhoff s voltage law states that the sum of all the voltage drops equals the source voltage Combining those two laws we see that any restriction in a circuit e g loose connector dam aged wire or corroded termi...

Page 314: ... ground connection 9f A similar ground side test on a tractor with a slow cranking starter motor can be con ducted between the engine block and the negative battery post See Figure 9 72 9g With the starter engaged this machine exhibited a voltage drop reading of 0 312 volts indicating a poor ground connec tion 9h Individually these readings should lead a technician to inspect the connection betwee...

Page 315: ... 0 1 volts and there was not a parasitic load on the engine e g PTO clutch that is not fully disengaged it would be logical for the tech nician to check voltage drop to the starter See Figure 9 74 With the starter motor engaged the voltage drop reading here is nearly 0 6 volts indicating a seri ous problem in the heavy gauge circuit between the starter and the battery 10g Checking voltage drop at ...

Page 316: ... Common Normally Open N O contacts do not complete a circuit when the switch is at rest plunger extended They close to complete a path through the switch when the plunger is depressed Normally Closed N C contacts complete a cir cuit when the switch is at rest plunger extended They open to break the path through the switch when the plunger is depressed Some Cub cadet switches contain more than one ...

Page 317: ... the DVOM to the diode or Ω scale See Figure 9 77 13c Attach the negative lead of the DVOM to the side of the diode with a band on it 13d Place the positive lead on the other side of the diode 13e There should be continuity See Figure 9 78 Figure 9 77 Diode scale Figure 9 78 Continuity Silver band 13f Switch the leads 13g The meter should indicate no continuity See Figure 9 79 13h If the results d...

Page 318: ...Chapter 9 Electrical 314 Electrical Schematic Main Wiring Harness w Kohler engine 725 04351 725 04365 ...

Page 319: ...Chapter 9 Electrical 315 Electrical Schematic Engine Harness w Kohler engine ...

Page 320: ...Chapter 9 Electrical 316 Electrical Schematic Main Harness w Caterpillar engine 725 04327 725 04365 ...

Page 321: ...Chapter 9 Electrical 317 Electrical Schematic Engine Harness w Caterpillar engine 725 04341 ...

Page 322: ...Chapter 9 Electrical 318 ...

Page 323: ...1 Front Drive System Differential Gearcase P N 6203 01 280 Parts and Service Manual Rev 0 Released 1 16 2012 ...

Page 324: ...General Maintenance It is recommended that the oil be changed once every 2000 miles To change the oil follow each step on the procedure listed below Oil Change Procedure 1 Remove the oil drain plug located on the bottom of the gearcase using a 5 16 hex key wrench 2 Let all the oil drain out of the unit Catch and discard the oil properly 3 Be sure to clean off any debris on the drain plug and reins...

Page 325: ...o check this simply run your fingers around the pole faces and make sure that the coil is correctly set below the metal insert along the entire circumference If you feel the coil above the pole faces replace the large output cover P N 6203 9U 107 If the coil is fully below the pole faces continue on to step 5 5 Check that the torsion spring part 28 is properly seated in the groove and notch of the...

Page 326: ...uld face out from the cover 6 Place the nylatron plastic shim plate part 35 on top of the armature plate and install the retaining ring part 14 back into the slot located on the large cover part 17 7 Insert the small needle roller bearing part 11 onto the dowel on the race output hub 8 Reassemble the clutch housing ring gear Part 20 the roll cage part 22 and the 14 rollers part 27 making sure that...

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