Cushman TURF-TRUCKSTER, Руководство по обслуживанию и ремонту

Страница: 106 / 263

4. Remove the shift shaft, lockwasher and shift fork.
5. Remove the two seals from the cover. Thoroughly
clean the cover and housing mating surface of all
sealant. Clean and inspect all parts for damage or
wear. Replace any damaged or worn parts.
REASSEMBLY (See Figure 4I-9)
1. Lubricate the shift shaft with clean grease. Rest
the shift fork and lockwasher on the shaft guide.
Install the shift shaft through the cover into the
shift fork.
2. Use a drift punch. Turn the shaft clockwise to
tighten the shaft on the fork.
3. Install new shaft seals into the cover. The lip of
the first seal must face inward. A short length of
3/4 inch PVC pipe will work very well as a seal
driver. The lip of the outer seal must face out-
ward.
4. Install the detent and spring and secure with
setscrew.
5. If repairs to the 2-speed auxiliary transmission are
required, leave the cover off the differential housing.
6. If no further repairs to the differential are required,
move the shift collar toward the rear cover. Put a
bead of Loctite 518 (Textron P/N 2811582)
sealant around the mating surface of the differen-
tial housing.
7. Install two 5/16-18 pilot studs in opposite holes as
shown in Figure 4I-10. Install the cover over the
pilot studs. Be sure the shift fork enters the groove
of the shift collar and remove the pilot studs.
8. Install and cover screws and washers. Tighten the
cover screws alternately and evenly to 14 to 18 ft-
lbs. (19 to 24 N.m).
2-SPEED AUXILIARY TRANSMISSION
DISASSEMBLY
1. If not previously removed for shift control cover
repairs described above, remove the six cover
retaining screws and flat washers and lift the shift
cover off the differential housing as shown in
Figure 4I-9.
2. Remove the front cover as described in Steps 1
thru 5 of “Differential Front Cover Repair.”
3. Refer to Figure 4I-11, remove the rear cover
screws, flat washers and gear ratio tag. Remove
the rear cover.
NOTE
Check the gear ratio tag; 14.21:1 ratio hypoid
rear axles have a spacer under rear cover. This
spacer is not used with 11.16: ratio axles.
4. Move the shift collar toward the front cover to
engage the direct gear drive. Hold the input shaft
(by gripping the yoke nut installed on the shaft) to
keep it from turning and loosen (do not remove)
the rear main shaft nut.
5. Remove the yoke nut and special washer from
the input shaft.
6. Starting at the rear cover end of the shaft, remove
the oil baffle and small pinion gear.
7. Use a large wrench to hold the large driven gear
stationary. Remove the large driven gear nut. This
nut is torqued to 200 to 225 ft-lbs. (271 to 305
N.m).
8. Remove the setscrew from the cluster gear jack-
shaft (setscrew is coated with thread sealant and
will require heavy torque to remove).
9. Pull the jackshaft out of the cluster gear and
housing.
10. Remove the cluster gear and spacer washers.
One spacer washer is used on the rear side and
two are used on the front side of the cluster gear.
Front spacers will drop into the housing; use a
magnet to retrieve the spacers.
11. Re-install the large driven gear nut to protect the
shaft threads and use a large brass drift and ham-
mer to strike the end of the shaft to “pop” the
large driven gear loose on the shaft.
12. Remove the pinion drive gear spacer and main
shaft retaining ring.
13. Install the nut on the main shaft to protect the
shaft threads. Use a rubber mallet to tap on the
main shaft. Tap the main shaft through the rear
bearing until the input shaft intermediate bearing
comes out of the bore of the housing.
DRIVE TRAIN
SECTION 4I. REAR AXLE
4I-8
Figure 4I-10. Installing Shift Control Cover