Troy-Bilt 21A-630B063 Service Manual Download Page 1

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Service Manual

MTD Products LLC - Product Training and Education Department

FORM NUMBER

769-01529

11/2004

Small Frame Troy-Bilt Tillers

Summary of Contents for 21A-630B063

Page 1: ...Service Manual MTD Products LLC Product Training and Education Department FORM NUMBER 769 01529 11 2004 Small Frame Troy Bilt Tillers...

Page 2: ......

Page 3: ...Forward return spring replacement 6 Transmission removal 7 Transmission disassembly 12 Transmission assembly 21 Forward Idler lever Pivot 32 Reverse clutch cable replacement 33 Reverse clutch cable ad...

Page 4: ......

Page 5: ...wering the tiller and refer to the Engine Owner s Manual for more information 2 FORWARD CLUTCH CABLE ADJUSTMENT 2 1 Remove the spark plug boot from the spark plug and ground it to the engine See Figur...

Page 6: ...he tension is too loose Continue through this section 2 10 If the second measurement spring coils extended of the forward clutch is too long more than 3 16 the tension is too tight Continue through th...

Page 7: ...FORWARD CLUTCH CABLE ASSEMBLY REPLACEMENT 3 1 Remove the spark plug boot from the spark plug and ground it to the engine See Figure 3 1 Figure 3 1 Spark Plug Boot Grounded Spark Plug 3 2 Loosen the he...

Page 8: ...he forward clutch cable to the lower cable mounting bracket using a 3 8 wrench and a 7 16 wrench See Figure 3 8 3 9 Slide the forward clutch cable out of the lower cable mounting bracket 3 10 Pivot th...

Page 9: ...work area Figure 4 1 Spark Plug Boot Grounded Spark Plug Figure 4 2 Hex Flange Screw Large Flat Washer Belt Cover Clutch Cable 4 4 Remove the belt from the engine drive pulley and forward idler pulley...

Page 10: ...the return spring from the right engine bracket using needle nose pli ers See Figure 5 4 5 5 Remove the lower hook of the return spring from the forward idler lever using needle nosed pliers See Figur...

Page 11: ...t cover 6 5 Set the belt cover aside 6 6 Remove both self tapping hex flange screws securing the tine hood to the right and left hood brackets using a 3 8 socket See Figure 6 6 Remove Drive Belt Remov...

Page 12: ...sting on the tines and not on the trailing shield 6 14 Raise the front of the tiller up until the wheel assemblies are off the ground See Figure 6 14 6 15 Remove both hair pins and clevis pins securin...

Page 13: ...Handlebar Secured 6 20 Remove both sets of hex screws securing the left and right engine brackets to the transmission using a 1 2 socket See Figure 6 20 6 21 Remove both self tapping hex screws securi...

Page 14: ...ch 6 28 Remove the forward return spring from the for ward idler lever See Figure 6 28 NOTE There are two holes at the bottom of the forward idler lever The right lower hole in the operators position...

Page 15: ...Pulley Key Front Support Washer Belleville Hex Screw Figure 6 31 Hex Screw Lock Washer Shoulder Washer Forward Lever Idler Pulley 6 33 Raise the rear of the transmission up and set it on a 2 x 4 block...

Page 16: ...a 1 2 socket See Figure 7 2 7 3 Remove the front transmission cover and clean it 7 4 Position a suitable oil drain pan directly in front of the bench See Figure 7 4 7 5 Rotate the transmission 180 to...

Page 17: ...ssembly using a 1 2 socket See Figure 7 9 Figure 7 8 Cover Gasket Wheel Worm Figure 7 9 Rear Transmission Cover Hex Screws 7 10 Remove the rear transmission cover gasket from the transmission using a...

Page 18: ...re the overall thickness of the rear bear ing shims using a dial caliper See Figure 7 18 7 19 Record the measurement _____ NOTE This is for future reference 7 20 Thoroughly clean the exposed portion f...

Page 19: ...r Bearing Race Drive Shaft Assembly Figure 7 25 Front Oil Seal Internal Snap Ring Race 7 27 Remove the front tapered roller bearing race by lightly tapping on the perimeter with a small punch and a ru...

Page 20: ...ssion oil seal bores are not damaged during removal 7 33 Remove the left and right retaining rings secur ing the wheel shaft in position using medium retaining ring pliers See Figure 7 33 7 34 Remove...

Page 21: ...ze wheel shaft bushing out of the transmis sion housing using a block of wood and a large hammer See Figure 7 38 NOTE The inner spacer will be damaged by the Hi Pro key 7 39 Remove the bronze bushing...

Page 22: ...y 7 44 Grasp the wheel shaft worm gear with one hand and remove the wheel shaft with the other NOTE Make certain the wheel shaft worm gear does not drop to the bottom of the transmission housing 7 45...

Page 23: ...re 7 48 Retaining Ring Tine Shaft 7 49 Remove the external shims from the right and left hand sides of the tine shaft using a small hook tool and a stick magnet See Figure 7 49 NOTE Two paper clips wi...

Page 24: ...aft to the right forcing the bronze tiller shaft bushing out of the transmis sion housing using a block of wood and a ham mer 7 57 Remove the bronze bushing and spacer from the tiller shaft NOTE The l...

Page 25: ...mission Housing Figure 8 2 Transmission Housing Protective Material Vice 8 3 Make certain all the drive shaft components are accounted for See Figure 8 3 8 4 Locate both hex flange screws that were se...

Page 26: ...is installed from inside the transmission housing 8 8 Carefully begin sliding the drive shaft assembly into the transmission housing until it reaches the drive shaft area See Figure 8 8 8 9 Slide the...

Page 27: ...et 8 14 Torque all of the hex screws to 100 In Lbs using a torque wrench and a 1 2 socket Figure 8 11 Rear Tapered Roller Bearing Race Figure 8 12 Rear Bearing Cap Hex Flange Screws Short Hex Flange S...

Page 28: ...above 8 23 Remove all three hex flange screws and wash ers securing the rear bearing cap in position using a 1 2 socket See Figure 8 23 8 24 Remove the rear bearing cap 8 25 Install the new rear bear...

Page 29: ...All Drive Shaft Assembly Components Removed Rear Bearing Cap Short Hex Screw Rear Bearing Cap Shims Rear Tapered Roller Bearing Race Drive Shaft Assembly Hex Flange Screws Support Washer Front Tapered...

Page 30: ...ng certain the lubrica tion cut a ways are facing in 8 41 Drive the second wheel shaft bronze bushing into the transmission housing until it is flush with the outside of the housing using a bushing dr...

Page 31: ...t 005 to 030 from the second recorded wheel shaft end play NOTE Shims of multiple thicknesses are used as required to obtain 005 to 030 allowable end play for the drive shaft 8 52 Record the new wheel...

Page 32: ...llation tool NOTE A 1 I D PVC pipe by 7 long works well as a wheel seal installation tool 8 65 Repeat the above wheel shaft oil seal installation procedures for the opposite side 8 66 Drive one of the...

Page 33: ...using using a bushing driver and hammer See Figure 8 73 NOTE A 1 I D PVC pipe by 7 long works well as a bushing installation tool Figure 8 69 Tine Shaft Bronze Bushing Worm Gear Spacer Spacer Figure 8...

Page 34: ...econd drive shaft end play 040 minus 005 to 030 equals remaining wheel shaft end play divided by two 8 87 Install the outer retaining rings onto the tine shaft using medium retaining ring pliers 8 88...

Page 35: ...n be used to keep them together 8 105 Apply a light coat of sealant to the inside mating face of the rear bearing cap Figure 8 96 Tine Shaft Seal Transmission Housing 8 106 Set the rear bearing cap ga...

Page 36: ...nsmission covers in position NOTE The front transmission cover s oil fill plug faces rearward 8 120 Secure the transmission covers to the transmis sion with the hex flange screws removed earlier using...

Page 37: ...formation refer to the Tuffy Tiller section UNIT FEATURES 6 5 Hp 4 cycle engine See the Image Below Protective bumper Power forward and reverse 16 tilling width 10 tine diameter Adjustable tilling dep...

Page 38: ...ing the reverse clutch cable to the belt cover bracket using two 1 2 wrenches See Figure 1 7 1 8 Remove the reverse clutch cable s Z fitting from the reverse idler arm NOTE The reverse return spring w...

Page 39: ...ully Engaged Threaded Clutch Cable End Hex Jam Nuts 2 5 Adjust both hex jam nuts until the exposed por tion of the reverse clutch cable is between 1 8 and 1 4 when it is engaged See Figure 2 5 2 6 Sec...

Page 40: ...n using a 1 2 socket and wrench See Figure 3 4 3 5 Remove the reverse drive belt from the reverse idler pulley 3 6 Remove all four self tapping screws securing the pulley belt guard to the left and ri...

Page 41: ...w Belleville Washer Transmission Pulley Figure 3 9 Transmission Pulley Inside Out Reverse Drive Belt Forward Drive Belt 4 REVERSE IDLER PULLEY ASSEMBLY 4 1 The following picture shows the reverse idle...

Page 42: ...Troy Bilt Small Frame Tillers 38 6 TRANSMISSION OIL FILL PLUG 6 1 The following picture shows the location of the oil fill plug for the transmission See Figure 6 1 Figure 6 1 Transmission Oil Fill...

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