T a b l e o f C o n t e n t s

4WD Output Disassembly and Assembly ........................................................... 24

Brakes Removal and Installation ......................................................................... 43
Center Valve Block Disassembly and Assembly ................................................. 33
Charge Pump Disassembly and Assembly ........................................................... 2
Charge Pump Removal and Installation ................................................................ 2
Control Arm and Damper Removal and Installation .............................................. 1
Differential (2WD) Disassembly and Assembly .................................................. 20
Differential (4WD) Disassembly and Assembly................................................... 21
Differential Lock Shaft Disassembly and Assembly ............................................ 19
General Specifications ......................................................................................... iv
Hydrostatic Flow Diagram Check Points ............................................................. 44
Hydrostatic Pump Inspection............................................................................... 35
Hydrostatic Transmission 2WD and 4WD ........................................................... 28
Hydrostatic Transmission Installation .................................................................. 35
Hydrostatic Transmission Motor Disassembly and Assembly (2WD) ................. 29
Hydrostatic Transmission Motor Disassembly and Assembly (4WD).................. 31
Hydrostatic Transmission Motor Installation ........................................................ 34
Inspection of Transaxle Case .............................................................................. 39
K92 Transmission Component Location............................................................... vi
Ordering Replacement Parts Online ..................................................................... ii
PTO Brake Removal and Installation .................................................................... 6
PTO Clutch Disassembly, Inspection and Assembly .......................................... 22
PTO Drive Train (Mid-PTO) Removal and Installation .......................................... 9
PTO Drive Train (Mid and Rear PTO) Removal and Installation ......................... 11
PTO Relief Valve Disassembly, Inspection and Assembly .................................... 6
PTO Relief Valve Removal and Installation ........................................................... 6
PTO Solenoid Valve .............................................................................................. 4
Rear Axle Assembly - Disassembly and Assembly ............................................ 42
Rear Axle Assembly Removal and Installation ................................................... 41
Rear PTO Assembly ............................................................................................ 17
Rear PTO Removal and Installation .................................................................... 14
Recommended Tools and Equipment .................................................................. iv
Serial Number Location ........................................................................................ iv
Transaxle (Right Cover) Disassembly and Assembly ......................................... 38
Transaxle Disassembly ....................................................................................... 36
Troubleshooting Guides ...................................................................................... 46

i
Ordering Replacement Parts Online
w w w . t u f f t o r q . c o m

At Tuff Torq, we offer our customers quality

products at a modest price. A manufacturer
of hydrostatic and gear drive transmissions
for the power equipment industry, Tuff Torq
offers a complete line of transmissions and
parts to help fit your needs.
Designed to meet the needs of our OEM custom-
Home ers, this web site is designed to assist service and re-
pair facilities in locating and ordering parts for Tuff
Torq manufactured transmissions. It also provides
transaxle parts identification, troubleshooting guides,
online ordering capabilities, as well as providing you
with a complete inventory of parts, service and same
day shipping.

If you are a registered user, please login (from the

Welcome Page) to access the parts ordering system.

If you are not a OEM customer or authorized service

distributor, you may need to contact your equipment
Page 1 manufacturer or authorized dealer. Select your brand
(from the Welcome page) and you will be directed to
the appropriate web site.

Navigating the web site:

To access Tuff Torq’s web site, type in www.

tufftorq.com from your Internet browser.
From the Home page, click on “Service” to enter the
Online Ordering page (Ref. Page 1)

From The Online Ordering page, click on “Click here

to enter service web site” to enter the Welcome page
Page 2 (Ref. Page 2).

From the Welcome page, login (for register users)

and follow the on screen instructions. Or, click on
“Catalog/Order” to enter Store Browser (Ref. Page
3).

From the Catalog/Order page, select your transaxle

model, e.g., K61. Click on “K61” to find the serial
number for your model (Ref. Page 4).

From the Model Series page, click on, your Model to

enter the Serial Number Range page (Ref. Page 5).
Page 3
ii
 Tuff Torq K92 Hydrostatic Transaxle
Having your Model, and Model Series, click on the
serial number to enter the Online Ordering page for
you Transaxle (Ref. 6).

Navigate through the exploded parts illustration until

the desired part has been identified. Take note of the
part’s figure number. Locate the part number in the
parts listing. You can add the part to your shopping
cart and return to the exploded illustration or—click
Page 4 on the item to go to the Product Explorer page for
additional detail about the part (Ref. Page 7).

Thank you for visiting and ordering online with Tuff

Torq.

Page 5

Page 6

Page 7
iii
Recommended Tools and Equipment Serial Number Location
1. Solenoid Valve Socket
2. Transmission Gear Spacer
3. Bushing, Bearing and Seal Driver Set
4. Press
5. Snap Ring Pliers
6. Knife-Edge Puller
7. Hoist
8. Silicon Sealant
9. Cure primer
10. Thread Lock and Sealer (Medium Strength)

General Specifications

iv
Tuff Torq K92 Hydrostatic Transaxle

v
K92 Transmission Component Location

Oil Port
(Fill Tube not Shown)

Forward/Reverse Main Transmission Case PTO Brake Cover

Control Valves

PTO Pressure
Test Port
Charge Pump

Control Arm Damper

4WD Assembly PTO Electrical

(Optional) Engagement Solenoid

Center Block Valve

Motor Case Assembly

Brake Arm/
PTO Pressure
Brake Assembly
Control Valve

Differential Lock Arm

Rear PTO Shaft
(Optional)

Differential Lock Shaft

Axle Assembly

K92 Hydrostatic Transaxle

vi
 Tuff Torq K92 Hydrostatic Transaxle
Control Arm and Damper Removal and Installation

Before beginning tear down clean work area thoroughly and

cover workbench with clean paper. This is extremely impor-
tant as just one grain of sand can cause damage to the Hy-
drostatic Rotating Group in the Transaxle.

Fig. 1, Control Arm and Damper Disassembly

A - Control Arm 4. Remove cap screw (C) and washer (B) from control
arm. (Fig. 1)
B - Washer
5. Remove control arm (A). (Fig. 1)
C - Main Cap Screw
6. Install control arm the same as removal, and install
D - Spring Locking Pin
washer and cap screw. Tighten cap screw (C) to 73 N•m
E - Washer (54 lb-ft).
F - Damper NOTE: If removed, use medium strength thread lock
G - Pivot Stud and sealer on pivot stud (G) threads.

H - Clevis Pin 7. Install damper with open end of clamp facing down.
I - Spring Locking Pin 8. Install remaining washers and spring locking pins.

1. Remove spring locking pins (D) and washers (E) from

both sides of damper (F). (Fig. 1) CAUTION: ALWAYS WEAR SAFETY GLASSES WHILE PER-
2. Slide damper off of pivot stud (G) and clevis pin (H). FORMING ANY MAINTENANCE ON TRANSAXLE!
Inspect and, if defective, replace damper as an assembly.
3. To remove control arm (A), remove spring locking pin (I)
and disconnect foot control rod (D) from control arm.

NOTE: Access to cap screw (C) is through hole in right

frame.

1
Charge Pump Removal and Installation
NOTE: Installation is done in the reverse order of removal.
• Tighten (2) short cap screws (A) to 25 N•m (18 lb-ft).
• Tighten long cap screw (Y) to 39 N•m (29 lb-ft).

NOTE: Approximate capacity of hydrostatic power train

is 7.5L (7.9 qt) for 2WD and 7.8L (8.2 qt) for 4WD and 9.0L (9.5
qt) for 4WD w/rear PTO.

Fig. 2, Charge Pump Rotor

IMPORTANT: Avoid damage! Do not drop pump

gerotor (P) or lose key (O). Damage to machined
surfaces will cause poor performance and premature failure.
(Fig. 2)
1. Remove drain plug to drain oil before starting any disas-
sembly of the transaxle.
2. Remove two (2) short (A) and one long (Y) cap screw.
(Fig. 3)

Charge Pump Disassembly and Assembly

Fig. 3, Charge Pump Disassembly

2
 Tuff Torq K92 Hydrostatic Transaxle
Charge Pump Disassembly and Assembly (continued)
A - Cap Screw (2 used), M10 x 65 6. Check small orifice in reducing valve (S) spool for
obstruction.
B - Plug
7. Replace parts if necessary.
C - O-ring
8. Remove plug (H) to remove charge pressure relief valve
D - Pump Body
parts (E, F, G, and I). (Fig. 3)
E - Pressure Valve
9. Inspect parts for scoring, wear or damage.
F - Spring
10. Replace parts if necessary.
G - O-ring
11. Inspect seal (X) and bushing (W) for wear or damage.
H - Plug
12. If bushing is removed, apply clean hydraulic oil to
I - Shims bushing and use a disk driver to install bushing to bot-
tom of bore.
J - Pin
13. If seal is replaced, apply clean hydraulic oil to new seal.
K - O-ring
Install seal with open side into pump body. Push seal to
L - O-ring bottom of bore.
M - O-ring 14. Apply clean hydraulic oil to all machined surfaces before
assembly.
N - Outer Rotor
O - Key NOTE: Installation is done in the reverse order of removal.
P - Inner Rotor
Q - O-ring
R - Plug
S - Reducing Valve
T - Spring
U - Reducing Plug
V - O-ring
W - Bushing
X - Seal
Y - Cap Screw, M10 x 105

NOTE: Charge pressure control valve and pressure

reducing valve can be removed when the charge pump
is in the machine. To inspect valve seats and bores, the
pump must be removed.
1. Disassemble all parts of charge pump (D). (Fig. 3)
2. Inspect O-rings (C, K, L, M, and Q) for cuts or damage.
Replace as necessary. (Fig. 3)

NOTE: Pump gerotor (N and P), seal (X), body (D), and
pressure reducing valve (S) parts must be replaced as a set.
3. Inspect gerotor charge pump parts (N - P). Replace
parts if worn, chipped, scored or damaged.
4. Remove plug (U) to remove pressure reducing valve
parts (V, S, and T). (Fig. 3)
5. Inspect parts for scoring, wear or damage.

3
Directional Control Valves
Removal and Installation: 3. Plunger pin must move freely.
4. Internal valve must move freely when valve is shaken.
5. Make sure orifice and all passages are free of any
obstruction.
6. Assemble parts.

IMPORTANT: Avoid damage! The reverse control

valve must be installed in the left port. The control
valve can be identified by a small orifice drilled into
a land between the two sets of valve passageways.

Fig. 4, Control Valves

1. Remove directional control valves (A). (Fig. 4)

NOTE: Installation is done in the reverse order of removal.

• Tighten directional control valves to 35 N•m (26 lb-ft).
Disassembly, Inspection and Assembly:

Fig. 6, Control Valve Location

PTO Solenoid Valve

Removal and Installation:

IMPORTANT: Avoid damage! Do not bend, twist or

damage solenoid armature. Do not damage machined sur-
faces or sharp edges of spool or sleeve. PTO will not function
or will function erratically if spool, sleeve or armature is dam-
aged.

Fig. 5, Control Valve Disassembly

A - Reverse Control Valve (with orifice)

B - Orifice
C - Forward Control Valve
D - O-ring
E - Backup Ring
F - O-ring

1. Disassemble parts from directional control valves.

2. Inspect O-rings and backup rings for damage. Fig. 7, Charge Pump Rotor

4
 Tuff Torq K92 Hydrostatic Transaxle

1. Disconnect solenoid connector (F) from wiring harness. A - Wave Washer

(Fig. 7)
B - Spool
2. Remove nut (A) and O-ring (B). (Fig. 8)
C - Sleeve
D - O-ring
E - Flats
F - Solenoid Armature
G - Gasket
H - Large Land on Sleeve
I - Oil Hole
J - Spring

Fig. 8, Solenoid Coil Disassembly

1. Disassemble PTO solenoid valve.
2. Inspect parts for wear or damage.
3. Remove solenoid cover (C), O-ring (D), and solenoid
3. Install spool into sleeve so the end with the oil hole is
coil (E). Note order and direction of valve components
toward the large land on the sleeve.
for reassembly.
4. Place spring into recess in end of spool.
4. Remove solenoid armature assembly. (Fig. 9)
5. Install sleeve assembly so smaller lands go into the PTO
5. Carefully remove valve components from PTO cover.
cover first.
NOTE: Check bottom of bore for “wave” washer. 6. Install gasket and O-ring.
6. Clean and inspect parts for damage. Replace if neces-
sary.
7. Place wave washer in case cover.
Disassembly, Inspection and Assembly:

NOTE: Sleeve and spool must be replaced as a set.

IMPORTANT: Avoid damage! Be sure large land (H) on sleeve

and oil hole in spool are facing away from PTO case cover.

Fig. 10, Solenoid Coil

7. Tighten solenoid armature to 22 N•m (195 lb-in.).

8. Slide solenoid coil (M) onto solenoid armature. Install
O-ring (L) and plastic nut (N) (do not tighten plastic nut
at this time.) (Fig. 10)

Fig. 9, PTO Solenoid Armature Disassembly

5
9. Position solenoid coil wire leads (P) to the right and PTO Relief Valve Disassembly, Inspection
approximately 45° above horizontal. and Assembly
IMPORTANT: Avoid damage! When tightening
plastic nut be sure to tighten nut to exact specifications. Nut
has a very low torque. Any overtightening will damage the
armature coil.

10. Tighten plastic nut (O) to 4.9 N•m (43 lb-in.). (Fig. 11)

Fig. 13, Relief Valve Assembly

1. Disassemble PTO relief valve. (Fig. 13)

2. Check relief valve plunger and bore for scoring, nicks or
burrs. Replace if necessary.
3. Install spring (B), gasket (C), relief valve plunger (A), and
plug (D) in PTO cover. (Fig. 13)

Fig. 11, PTO Electrical Solenoid PTO Brake Removal and Installation
NOTE: Approximate capacity of hydrostatic power train
is 7.5L (7.9 qt) for 2WD and 7.8L (8.2 qt) for 4WD and 9.0L (9.5
PTO Relief Valve Removal and Installation qt) for 4WD w/rear PTO.

CAUTION: Avoid Injury! Allow transaxle to cool before drain-

ing fluid. Hot fluid can cause serious burns.

Fig. 12, Relief Valve Plug

1. Remove relief valve plug. (Fig. 12)

2. Install relief valve plug (A) and tighten to 25 N•m (19
lbft).

Fig. 14,Transaxle/Rear PTO Cover

6
 Tuff Torq K92 Hydrostatic Transaxle
1. Remove plug (B) to drain oil from transaxle. (Fig. 14)

NOTE: If rear PTO is installed, remove necessary rear PTO

components before rear transaxle cover removal. (See “Rear
PTO Removal and Installation” on page 12.)
2. Remove optional rear PTO (A), if installed. (See “Rear PTO
Removal and Installation” on page 12.) (Fig. 14)
3. Remove rear transaxle cover (C). (Fig. 14)
4. Remove control arm damper (D), (Fig. 14-15), to gain
access to (3) cap screws (K), (Fig. 15), holding PTO brake
cover (J), (Fig. 15), to transaxle side cover. (See “Control
Arm and Damper Removal and Installation” on page 1.)

Fig. 15, PTO Brake Cover Removal

Fig. 16, PTO Brake Cover Kit

NOTE: Installation is done in the reverse order of diassembly.

7
PTO Brake Disassembly, Inspection and Assembly (Fig. 17)

Transaxle Case

Side Cover

Fig. 17, PTO Brake Disassembly

CAUTION: Avoid Injury! PTO brake cover is spring loaded.

Remove cap screws evenly to release spring force.

A - Collar, Brake Pin F - Stopper

B - O-ring G - Spring, Inner
C - Pin, PTO Brake H - Spring, Middle
D - Snap Ring (2 used) I - Spring, Outer
E - Piston J - Cover
K - Cap Screw (3 used)

8
 Tuff Torq K92 Hydrostatic Transaxle

L - O-ring NOTE: Remove necessary rear PTO components before rear

transaxle cover removal. (See “Rear PTO Removal and Instal-
M - PTO Brake Shoe lation” on page 14.)
N - PTO Clutch Assembly
2. Remove optional rear PTO (A), if installed. (See “Rear PTO
1. Carefully pull piston assembly from case using a pliers. Removal and Installation” on page 14.) (Fig. 18)
Do not damage pin. (Fig. 17)
3. Remove rear transaxle cover (C). (Fig. 18)
2. Remove PTO clutch assembly (N) and brake shoe (M)
together.

NOTE: PTO brake pin, piston, springs, and O-rings, etc.,

(parts C thru I), must be replaced as a set.
3. Check pin and piston for burrs, scoring or wear.
4. Replace brake shoe if grooves in shoe contact surface
are not visible.
5. Inspect O-rings for cuts or damage.
6. Inspect springs for cracks or damage.
7. Apply petroleum jelly to O-rings and seal on end of PTO
clutch shaft.
8. Install piston assembly and clutch assembly.
9. Clean mating surface of side cover and transaxle case.
Be sure threaded holes are clean.
10. Apply a bead of silicon sealant to cover mating of sur-
face.
Fig. 18,Transaxle Cover
IMPORTANT: Avoid damage! Be sure side cover is aligned
with transaxle case and installed within 3 mm (1/8 in.) of
case before tightening cap screws. Major damage can occur 4. Remove PTO clutch assembly (A). (Fig. 19)
to cover and/or case if cover is not installed properly before 5. Remove PTO idler gear assembly (N). (Fig. 19)
tightening cap screws.
6. Remove PTO gear (K). (Fig. 19)
Transaxle Cover Cap Screw Torque Specifications:
7. Left axle must be removed to remove PTO output shaft
• Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) assembly (L), (See “Rear Axle Assembly Removal and
• New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Installation” on page 41.)

PTO Drive Train (Mid-PTO) Removal and

Installation
NOTE: Approximate capacity of hydrostatic power train
is 7.5L (7.9 qt) for 2WD and 7.8L (8.2 qt) for 4WD and 9.0L (9.5
qt) for 4WD w/rear PTO.

Removing:
CAUTION: Avoid Injury! Allow transaxle to cool before drain-
ing fluid. Hot fluid can cause serious burns.

1. Remove plug (B) to drain oil from transaxle. (Fig. 18)

9
PTO Drive Train (Mid-PTO) Removal and Installation (continued)
8. Inspect ball bearings and needle bearing for smooth A - PTO Clutch Assembly
rotation.
B - Snap Ring
NOTE: Idler gear (N) and shaft (O) must be replaced as a set. C - Needle Bearing
(Fig. 19)
D - Washer
9. Inspect gears and splines for missing or chipped teeth,
E - Seal
wear or damage. Replace parts if necessary.
F - Needle Bearing
G - Washer
H - Cap Screw
I - Ball Bearing
J - Snap Ring
K - Mid-Mount PTO Gear
L - PTO Output Shaft
M - Snap Ring
N - PTO Idler Gear
O - PTO Idler Shaft
P - Washer

Fig. 19, Rear PTO Cover Removed

Fig. 20, PTO Drive Train (Mid-PTO) Disassembly

10
 Tuff Torq K92 Hydrostatic Transaxle
Installing: PTO Drive Train (Mid and Rear PTO) Remov-
1. If replaced, install new needle bearing (F) from inside al and Installation
case with bearing identification marks toward the inside
NOTE: Approximate capacity of hydrostatic power train
of the case. Push bearing tight against shoulder in bore.
is 7.5L (7.9 qt) for 2WD and 7.8L (8.2 qt) for 4WD and 9.0L (9.5
(Fig. 20)
qt) for 4WD w/rear PTO.
2. Install new seal (E) with the open, spring side towards
the inside of the case. (Fig. 20) Removing:
3. Push seal against shoulder in bore.
CAUTION: Avoid Injury! Allow transaxle to cool before drain-
4. Install mid-mount PTO gear (K) so side with the longer ing fluid. Hot fluid can cause serious burns.
center hub is towards bearing. (Fig. 20)
1. Remove plug to drain oil from transaxle (AA). (Fig. 21)
5. Clean mating surfaces of rear cover and case. Be sure
threaded holes are clean and two O-rings are in position
in rear cover.
6. Apply petroleum jelly to seal on shaft of PTO clutch as-
sembly.
7. Apply a bead of silicon sealant to cover mating surface.

IMPORTANT: Avoid damage! Be sure rear cover is aligned

with transaxle case and installed within 4 mm (1/8 in.) of
case before tightening cap screws. Major damage can occur
to cover and/or case if cover is not installed properly before
tightening cap screws.
8. Install transaxle drain plug. Refill transaxle with ap-
proximately 9.0L (9.5 qt) using ATF Type F as required) to
crosshatched area of dipstick.
Rear Cover Cap Screw Torque Specifications:
• Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
• New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
• Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)

Fig. 21, PTO Drive Train (Mid and Rear PTO) Removal

NOTE: Remove necessary rear PTO components before rear

transaxle cover removal. (See “Rear PTO Removal and Instal-
lation” on page 14.)
2. Remove rear PTO (AD). (See “Rear PTO Removal and
Installation” on page 14.)
3. Remove (9) cap screws (AC) to remove rear cover (AB).
(Fig. 21)
4. Remove PTO clutch assembly (A). (Fig. 22)

IMPORTANT: Avoid damage! When removing snap ring (B),

be sure not to lose needle bearing (C) or washers (D).
5. Remove PTO idler gear assembly (U). (Fig. 22)
6. Remove snap ring (L), spline collar (K), and remove mid-
mount and rear-mount PTO gear assembly (I). (Fig. 22)
7. Left axle must be removed to remove PTO output shaft
assembly (R), (Fig. 20). Inspect ball bearings and needle
bearings for smooth rotation.
11
PTO Drive Train (Mid and Rear PTO) Removal and Installation (continued)
8. Inspect gears and splines for missing or chipped teeth,
wear or damage. Replace parts if necessary.

Fig. 22, PTO Drive Train (Mid and Rear PTO) Disassembly

A - PTO Clutch Assembly K - Spline Collar

B - Snap Ring L - Snap Ring
C - Needle Bearing M - Cap Screw (2 used)
D - Washer N - Washer
E - Seal O - Needle Bearing
F - Snap Ring P - Washer
G - Spacer Q - PTO Idler Shaft
H - Ball Bearing R - PTO Output Shaft
I - Mid-Mount and Rear-Mount PTO Gear S - Ball Bearing
J - Needle Bearing T - Snap Ring
U - PTO Idler Gear

12
 Tuff Torq K92 Hydrostatic Transaxle
Installing:
1. Clean mating surfaces of rear case and transaxle case. Be
sure threaded holes are clean. (Fig. 23) Rear PTO Case
Mating Surface
2. Apply petroleum jelly to seal on shaft of PTO clutch as-
sembly (E). (Fig. 22)
3. Apply a bead of silicon sealant to rear case mating sur-
face. (Fig. 23)

IMPORTANT: Avoid damage! Be sure rear case is aligned

with transaxle case and installed within 4 mm (1/8 in.) of case
before tightening cap screws. Major damage can occur to
PTO case and/or transaxle case if not installed properly be-
fore tightening cap screws.
4. Carefully position the rear case (A) on the transaxle and
onto the lower dowel pin (H). Use a pry bar between the
PTO and frame to carefully move the PTO approximately
1.5 mm (1/16-in.) to the right to align the top of the
case with the upper dowel pin (G). Secure with (14) cap
screws (E). (Fig. 24)
Rear Cover Cap Screw Torque Specifications:
Fig. 23, Rear PTO Cover and Transaxle Case Assembly
• Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
• New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
• Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
5. Apply a bead of silicon sealant to PTO gear case (A) mat-
ing surface.
6. Carefully position the PTO cover (B) on the PTO case (A).
Align the top of the cover with the upper dowel pin (F)
and onto the lower dowel pin (I). Secure with (3) cap
screws (C) and (10) cap screws (D). (Fig. 24)

IMPORTANT: Avoid damage! Be sure cover is aligned with

transaxle case and installed within 4 mm (1/8 in.) of case be-
fore tightening cap screws. Major damage can occur to cover
and/or case if cover is not installed properly before tightening
cap screws.
Rear PTO Gear Case Cap Screw Torque Specifications:
• Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
• New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Fig. 24, Rear PTO Cover Assembly
8. Install transaxle drain plug. Refill transaxle with ap-
proximately 9.0L (9.5 qt) using ATF Type F as required) to
crosshatched area of dipstick.
9. Install any additional items removed prior to PTO.

13
Rear PTO Removal and Installation
NOTE: Approximate capacity of hydrostatic power train is
9.0L (9.5 qt) for 4WD w/rear PTO.

Removing:
CAUTION: Avoid Injury! Allow transaxle to cool before drain-
ing fluid. Hot fluid can cause serious burns
1. Remove plug (AA) to drain oil from transaxle. (Fig. 25)

Fig. 26, PTO Rear Case Cover

Disassembly and Assembly:

1. Remove cover from PTO gear case (C). (Fig. 27)
2. Remove cap screw (A) and plate (B), and pull shifter
shaft (E) from PTO gear case (C). Replace O-ring on
shifter shaft and apply thin coating of clean hydraulic
oil, before reinstalling. (Fig. 27)

Fig. 25, Rear PTO Gear Case Cover

2. Remove (14) cap screws (AC) and PTO gear case cover
assembly (AD). (Fig. 25)

NOTE: Remember to install two different sized cap screws in

original holes as removed.
3 Remove PTO drive gear (G). Inspect parts and replace as
necessary. (Fig. 26)
4. Remove and replace oil seal (S) from cover. Install new
seal into cover with the closed side of the seal into the
bore first. Use a disk driver to push seal to bottom of
bore. (Fig. 26)

Fig. 27, Rear PTO Gear Case Assembly

14
 Tuff Torq K92 Hydrostatic Transaxle
3. Remove shift collar (F) and shifter fork (N) assembly 7. With fork groove of shift collar away from case, install
together. (Fig. 27) shifter fork and collar. Be sure arm of shifter shaft (E) fits
into slot of shifter fork. (Fig. 37)
NOTE: If shift collar replacement is necessary, the rear PTO
idler gear and rear PTO input gear must be replaced also. The NOTE: Install bearings with writing/numbers facing gears in
three gears are available as a set. cover assembly.
4. Remove tow relief valve (L) if necessary. Remove and 8. Using a rubber mallet, tap the opposite side of the PTO
replace O-ring. (Fig. 28) cover to unseat the idler gear, bearings, and shaft as a
single item. (Fig. 30)

Fig. 30, Idler Gear Set

9. From reverse side of PTO case, drive out the PTO idler
Fig. 28,Tow Relief Valve
pinion gear , PTO input gear, idle shaft, and bearings
5. Remove (10) cap screws (AC) and removal PTO rear case from their seated position as a single item. Press bear-
from transmission case. (Fig. 29) ings from shaft and inspect all components for wear or
damage, replace as necessary. (Fig. 31)

Fig. 31, Input Gear Set

10. From reverse side of the PTO case, drive out the rear PTO
shaft, PTO gear, and bearings from case as a single item.
(Fig. 32)

Fig. 29, Rear PTO Gear Case Removal

6. If shifter fork (N), see fig. 27, was disassembled, install
spring (Y) and ball (V) in fork. While compressing ball
and spring, install fork shaft (CC). Be sure ball fits into
grooves of shaft. (Fig. 37)
15
Rear PTO Removal and Installation (continued)
13. Remove snap ring (L), idler gear (G), snap ring (H), press
bearing (I), and press bearing (K) from shaft (J). Inspect
all components for wear or damage, replace as neces-
sary. (Fig. 35)

NOTE: Recall writing/numbers on all outer bearing races,

and install bearings in reverse order as removal.

Fig. 32, Rear PTO Shaft Assembly

11. Remove press bearing (S) from the PTO shaft (X); then,
remove PTO gear (T), snap rings (Z), and press bearing
(W) from PTO shaft. Inspect all components for wear or
damage, replace as necessary. (Fig. 33)

Fig. 35, Rear PTO Idler Gear Disassembly

14. If necessary, remove ball switch (W) and O-ring.
(Fig. 36)
• If removed, install O-rings and ball switches (W). DO NOT
overtighten. Tighten to 34 N•m (25 lb-ft).

Fig. 33, Rear PTO Shaft Disassembly

12. Remove press bearing (M) from idler shaft (P). Remove
washer (N), PTO input gear (R), and idler pinion gear (O).
Remove press bearing (U) and remove washer (Q) from
idler shaft (P). Inspect all components for wear or dam-
age, replace as necessary. (Fig. 34) Fig. 36, Ball Switches
15. Inspect all parts and replace as necessary. Assembly is
reverse order of disassembly.

Fig. 34, Rear PTO Pinion/Input Gear Disassembly

NOTE: If rear PTO input gear (R), see fig. 34, replacement is
necessary, the shift collar (F), see fig. 36, and rear PTO idler
gear (G), see fig. 35, must be replaced also. The three gears are
available as a set. Rear PTO gear (T), see fig. 33, and rear PTO
idler pinion (O), see fig. 34, must be replaced as a set.

16
 Tuff Torq K92 Hydrostatic Transaxle
Rear PTO Assembly

Fig. 37, Rear PTO Disassembly

A - Cap Screw P - Shaft

B - Spring Q - Washer
C - PTO Case R - Input Gear
D - O-ring S - Bearing
E - Shifter Shaft T - Rear PTO Gear
F - Spring U - Bearing
G - Idler Gear V - Ball
H - Snap Ring W - Bearing
I - Bearing X - Rear PTO Shaft
J - Idler Shaft Y - Spring
K - Bearing Z - Snap Rings
L - Snap Ring AD - Rear PTO cover
M - Bearing BB - Fork Kit
N - Washer CC - Fork Shaft
O - Idler Pinion Gear DD - Seal

17
Rear PTO Removal and Installation (continued)

Installing:
NOTE: Installation is done in the reverse order of diassembly.
Additional information can be found by refering to the “Rear
PTO Removal and Installation” removal section, starting on
page 14.
1. Clean mating surfaces of cover (AD) and gear case (C).
Be sure threaded holes are clean. (Fig. 37)
2. If removed, install gear sets in the reverse order of their
disassembly. (Fig. 37)
3. Apply a bead of silicon sealant to any mating surfaces to
be assembled.

IMPORTANT: Avoid damage! Carefully lower cover assem-

bly onto case, making sure bearings fit into bores and gears
mesh properly. Be sure cover is installed within 3 mm (1/8 in.)
of case before tightening all cap screws to 25 N•m (18 lb-ft).
Major damage can occur to cover and/or case if not properly
aligned before tightening cap screws.
4. Install PTO assembly on the two alignment bushings,
and tighten tenF), and three M8 x 50 (E) cap screws to
specification below.
5. Install transaxle drain plug. Refill transaxle with approxi-
mately 9.0L (9.5 qt) using ATF Type F to crosshatched
area of dipstick.
Specifications:
• M8 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
• M12 Bolts. . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)

18
 Tuff Torq K92 Hydrostatic Transaxle
Differential Lock Shaft Disassembly and Assembly

Fig. 38, Differential Lock Shaft Disassembly

A - Snap Ring (2 used) H - Roll Pin

B - Spring I - Shift Collar
C - Sleeve (2 used) J - Cap Screw
D - Fork K - Plate
E - Shaft L - Fulcrum, Differential Lock
F - Spring M - Washer
G - Washer N - Cotter Pin
O - Seal
1. Remove roll pin (H), washer (G), and spring (F). (Fig. 38)
NOTE: Install long hub of fork towards transaxle.
2. Remove snap rings (A), sleeves (C), spring (B), shaft (E),
and fork (D). (Fig. 38)
CAUTION: Avoid Injury! Springs are under compression.
3. Inspect shaft (E) and fork for wear or damage. Replace Carefully remove roll pin and release spring force slowly to
parts as necessary. (Fig. 38) prevent personal injury.

NOTE: Installation is done in the reverse order of removal.

19
Differential (2WD) Disassembly and Assembly

Fig. 39, Differential (2WD) Disassembly

A - Ball Bearing N - Differential Lock Collar

B - Bevel Input Gear O - Left Ball Bearing
C - Final Pinion Shaft 1. Use a puller to remove left ball bearing from differential
holder.
D - Ball Bearing
2. Inspect differential components.
E - Right Ball Bearing
3. Bearings must rotate free and smoothly. Replace as
F - Final Gear
necessary.
G - Right Differential Gear
4. Check differential components for wear or damage. If
H - Differential Carrier replacement is necessary, all parts must be replaced as
set.
I - Pins (2 used)
5. Inspect differential lock collar for wear or loose or
J - Pinion Gear (2 used)
sheared off pins.
K - Left-Notched Differential Gear
6. Check differential holder (L) and carrier (H) for wear,
L - Differential Holder cracks or damage. (Fig. 39)
M - Cap Screws w/Washers (8 used)
20
 Tuff Torq K92 Hydrostatic Transaxle
7. Inspect final gear (F) for worn or damaged teeth. 10. Install final gear on differential holder and carrier with
(Fig. 39) the deeper offset of gear center away from the holder.
Tighten eight differential cap screws (M) to 88 N•m (65
8. Inspect ball bearings (A and D) for smooth rotation.
lbft).
(Fig. 39)
11. Install differential lock collar (N) and left and right bear-
NOTE: Final pinion shaft (C) and final gear (F) must be re- ings (O). Push bearing tight against shoulder of differen-
placed as a set. Bevel input gear (B) and bevel input pinion tial holder. (Fig. 39)
(not shown) must be replaced as a set.
12. Install remaining components.
9. Check bevel input gear (B) and final pinion shaft (C) for
worn or damaged condition. Replace parts as necessary. NOTE: Use medium strength thread lock and sealer.
(Fig. 39)

Differential (4WD) Disassembly and Assembly

Fig. 40, Differential (4WD) Disassembly

A - Ball Bearing I - Washer (2 used)

B - Bevel Input Gear J - Pinion Gear (2 used)
C - Final Pinion Shaft K - Differential Pinion Shaft
D - Ball Bearing L - Left-Notched Differential Gear
E - Ball Bearing (2 used) M - Final Gear
F - Differential Holder, Right N - Differential Holder, Left
G - Liner (2 used) O - Washers (8 used)
H - Right Differential Gear P - Cap Screws (8 used)
Q - Differential Lock Collar
21
Differential (4WD) Disassembly and Assembly (continued)
1. Use a puller to remove ball bearings (E) from differential NOTE: Final pinion shaft (C) and final gear (M) must be re-
holders (F and N). (Fig. 40) placed as a set. Bevel input gear (B) and bevel input pinion
(not shown) must be replaced as a set.
2. Inspect differential components.
9. Check bevel input gear (B) and final pinion shaft (C) for
3. Bearings must rotate free and smoothly. Replace as
worn or damaged condition. Replace parts as necessary.
necessary.
10. Install final gear on differential holder and carrier with
4. Check differential components for wear or damage. If
the deeper offset of gear center away from the holder.
replacement is necessary, all parts must be replaced as
Tighten eight differential cap screws (P) to 88 N•m (65
set.
lbft).
5. Inspect differential lock collar for wear or loose or
11. Install differential lock collar (Q) and left bearing (E).
sheared off pins.
Push bearing tight against shoulder of differential
6. Check differential holders (F and N) and differential holder.
pinion shaft (K) for wear, cracks or damage. (Fig. 40)
12. Install remaining components.
7. Inspect final gear (M) for worn or damaged teeth.
NOTE: Use medium strength thread lock and sealer.
NOTE: Pinion gears (J) (2 used), washers (I) (2 used), and dif-
ferential pinion shaft (K) must be replaced as a set.
8. Inspect ball bearings (A and D) for smooth rotation.

PTO Clutch Disassembly, Inspection and Assembly

Fig, 41, PTO Clutch Disassembly

22
 Tuff Torq K92 Hydrostatic Transaxle

A - Ball Bearing
B - Snap Ring
C - Clutch Shaft
D - Needle Bearing
E - Washer
F - O-ring
G - Piston
H - Spring
I - Washer
J - Snap Ring
K - Input Shaft Collar
L - Snap Ring
M - Thick Steel Plate
Fig. 42, Clutch Disassembly
N - Friction Plate
O - Spring
10. Check steel plates for scoring, discoloration, warping or
P - Pin
wear.
Q - Steel Plate
11. Replace worn or damaged springs.
R - Clutch Gear/Hub
12. Check input shaft collar for burrs, wear or damaged
S - Washer teeth or splines.
T - Seal Ring 13. Check clutch pack wear. Assemble parts.

1. Remove PTO clutch assembly. (See “PTO Brake Removal

and Installation” on page 6.)
2. Remove large snap ring and thick steel plate.
3. Remove parts.

NOTE: Friction plates, springs, steel plates and pins must be

replaced as a set.
4. Replace clutch gear/hub if brake surface is badly scored
or teeth are chipped or damaged.

CAUTION: Avoid Injury! Piston is under spring force. Use

care during disassembly. Fig. 43, Clutch Disassembly
5. Remove piston from clutch gear/hub. Use a transmis-
sion gear spacer (X) to compress spring (U) and washer
(V) in a vise. Remove snap ring (W) and slowly release 14. Put clutch gear/hub on bench so steel and friction
force of spring. (Fig. 42) plates are against snap ring. Measure clearance between
inner steel plate and bottom of clutch gear/hub.
6. Remove remaining clutch parts.
15. If clearance measures 2.7 mm (0.106 in.) or more, re-
7. Check bearings for smooth rotation. place PTO clutch plates.
8. Inspect clutch gear for worn or damaged teeth. 16. Apply clean hydraulic oil to all parts.
9. Check inner piston bore for scoring or wear.
NOTE: Installation is done in the reverse order of removal.
23
4WD Output Disassembly and Assembly
1. Drain transaxle. 6. Remove the first press bearing (E), gear (Y), washer (Z),
and gear (AA) from 4WD reduction shaft (X). Remove
CAUTION: Avoid Injury! Allow transaxle to cool before drain- 4WD reduction shaft (X), and the second press bearing
ing fluid. Hot fluid can cause serious burns. (E) from the 4WD gear box as a single item. (Fig. 46)
2. Remove bolt/washer (I, J) and drain the 4WD gear box. 7. Remove press bearing (E) from 4WD reduction shaft (X).
3. Remove (11) bolts (H), bolt (AK), and bolt (AH) from 4WD
NOTE: When reinstalling, take care to place gears in their
cover. original order; with the thicker gear in front (with raised sur-
4. Remove 4WD cover (A). face towards the bearing) and the thinner gear behind.

NOTE: To avoid damage, during separation, to the cover

and/or the gear box, use the pry points shown in fig. 44.

Fig. 46, 4WD Cover Removal

8. Remove snap rings (V) and (AM); then, gear (R) from
shaft (S). Remove snap ring (AN) and remove (S, T, U, V,
W, and AO) as a single item from the 4WD gear case.
Fig. 44, 4WD Cover Removal
9. Remove press bearing (AO), collar (W), snap ring (V),
press bearing (U), and collar (T) from shaft (S). (Fig. 47)
5. Remove the drive gear (AC) from motor shaft. NOTE: Flat end of shift collar goes toward bearing.
10. Clean bearings in a suitable solvent. Dry with com-
pressed air.

IMPORTANT: Avoid damage! DO NOT spin bearing using

compressed air. Damage to bearing balls, cage, and races
could result.
11. Inspect bearings for discolored, burned, balls and/or
races. Check balls and races for spalling or cracking. Roll
bearing by hand to check for rough turning or excessive
looseness or play between balls and races. Replace bear-
ings as required.

Fig. 45, 4WD Cover Removal

NOTE: Snap ring (AD) on motor shaft does not need to be

removed for the 4WD gear case removal. Unless replacement
is necessary. (Fig. 52).

Fig. 47, 4WD Cover Removal

24
 Tuff Torq K92 Hydrostatic Transaxle

12. Remove bolt (F) and keeper plate (AP) from the 4WD 16. Remove the bearing (E) from the 4WD output shaft (N).
cover.
17. Carefully remove front shift collar (Q) from 4WD output
13. Use drift to drive out spring pin (L) and roll pin ( M) shaft. As separation occurs the detent balls (AR) and
securing 4WD shift arm (C) to 4WD shift shaft (G); then, spring (AQ) will become visible. (Fig. 50)
remove 4WD shift arm from the 4WD shift shaft. Replace
if damaged or worn. CAUTION: Detent Balls are under pressure from spring while
assembled. Care should be taken during disassembly to in-
NOTE: Replace O-ring (K, see fig. 52) on 4WD shift shaft sure that they do not fly out, possibly causing damage and/or
when reinstalling. injury. Safety glasses should be worn at all times while work-
ing on the transaxle.

Fig. 50, 4WD Cover Removal

Fig. 48, 4WD Cover Removal

18. From the 4WD gear case (B), remove (2) bolts with wash-
14. Slide the 4WD shift shaft (G) down into the cover until ers (AG and AI). Remove (2) bolts (H) and (1) bolt with
bearing shift block (P) is clear of the front shift collar (Q). washer (AL and AI). (Fig. 51)
Remove the bearing shift block; then, pull out the front 19. Remove 4WD gear case from motor case assembly.
shift collar (Q) and 4WD output shaft (N). Drive out roll
pin (M) from 4WD shift arm (O) by aligning roll pin with
open port in 4WD cover (bolt (I) must be removed).
Replace if damaged or worn. (Fig. 49)
15. Remove 4WD shift arm from 4WD shift shaft by pulling
shaft up from the 4WD cover.

Fig. 51, 4WD Cover Removal

20. Measure OD of bearing surface. If not within specifica-

tions, replace front wheel drive output shaft.

Fig. 49, 4WD Cover Removal NOTE: Replace seal (D) if output shaft is removed. (Fig. 50).

25
4WD Output Disassembly and Assembly (continued)
21. Measure ID of pilot hole. If not within specifications,
replace 4WD output shaft.
22. Inspect sleeve on 4WD output shaft (N) for wear. Re-
place, as necessary.
23. Inspect splines on 4WD output shaft (N) and shift collar
(Q) for damage. Replace as required. (Fig. 52)
24. Inspect groove in shift collar (Q) for scoring or damage.
Replace as required.
Specifications for 4WD Output Shaft:
• OD at Bearing . . . . . . 24.98 - 25.0 mm (0.983 - 0.984 in.)
• ID Pilot Hole . . . . . . . 17.0 - 17.02 mm (0.669 - 0.670 in.)
25. Measure shaft bore in 4WD cover. If not in specifications,
replace housing.
26. Measure OD of shaft in bearing area. If not in specifica-
tions, replace shaft.
Specifications:
• Shaft OD . . . . . . . . . . . 16.93 - 17 mm (0.667 - 0.669 in.)
• 4WD Cover Shaft Bore ID 17 - 17.043 mm
(0.669 - 0.671 in.) 4WD Output Disassembly
Assembly and Installation: A - 4WD Front Cover
Assembly and installation of the 4WD output assembly is car- B - 4WD Gear Case
ried out in reverse order of disassembly and removal.
C - Shift Arm 4WD
Replace the gasket (AE, see fig. 52), and gasket (AF, only if
4WD gear case was removed) or use a thin bead of silicone D - Seal
sealant between motor case assembly and 4WD gear case. E - Bearing
Also, between 4WD gear case and 4WD cover.
F - Bolt

Refill transaxle w/approximately 7.8L (8.2 qt) for 4WD and G - Shaft Shift 4WD
9.0L (9.5 qt) for 4WD w/rear PTO. Use ATF Type F and fill to H - Bolt
crosshatched area of dipstick.
I - Bolt (12 mm)
J - Gasket
Tighten cap screws to specification.
K - O-ring
Torque Specification:
L - Spring Pin
• Cap Screws. . . . . . . . . . . . 16 - 22 N•m (144 - 192 lb-in.)
M - Spring Pin
N - Shaft Front Drive
O - Arm Shift 4WD
P - Block Shift Bearing
Q - Collar Front Shift
R - Gear 4WD
S - Shaft 4WD
T - Collar

26
 Tuff Torq K92 Hydrostatic Transaxle
4WD Output Disassembly (continued)

Fig. 52, 4WD Output Disassembly

U - Bearing AG - Bolt
V - Snap Ring AH - Bolt
W - Collar AI - Washer
X - Shaft Reduction 4WD AJ - Guide Pin
Y - Gear 4WD AK - Bolt
Z - Washer AL - Bolt
AA - Gear AM - Ring
AB - Bearing AN - Ring
AC - Gear AO - Bearing
AD - Ring AP - Keeper Plate
AE - 4WD Gear Box Gasket AQ - Spring
AF - 4WD Gear Box Cover Gasket AR - Detent Ball
27
Hydrostatic Transmission 2WD and 4WD
Hydrostatic Transmission Removal: Hydrostatic Transmission Motor Removal:
1. Remove charge pump. (See “Charge Pump Removal and
Installation” on page 2)

IMPORTANT: Avoid damage! Do not drop or damage pump

valve plate when removing center valve block assembly. Do
not nick or scratch lapped or machined surfaces of the valve
plates or cylinder block components. The slightest damage
can cause poor performance.

Fig. 54, 2WD Shown (4WD similar)

2WD Shown
1. Remove retaining ring (B), bevel input pinion (C), and
ball bearing (A).
2. Inspect bearing for smooth rotation.

NOTE: Bevel input pinion and bevel input gear must be re-
placed as a set.
3. Check pinion for wear or damage.
Fig. 53, 2WD Shown (4WD similar)
4. Replace retaining ring if ring is distorted during remov-
2. Remove cap screws (A) — leaving in place 2 cap screws al.
(D). Carefully remove center valve block (B) and motor
assembly from transaxle.
3. Replace gasket (C) if torn or damaged.

28
 Tuff Torq K92 Hydrostatic Transaxle
Hydrostatic Transmission Motor Disassembly and Assembly (2WD)

Fig. 55, Hydrostatic Transmission Motor Disassembly (2WD)

A - Cap Screw (2 pieces) S - Piston

B - Seal Cap T - Gasket
C - Snap Ring U - Thick Thrust Plate
D - Snap Ring V - Thrust Bearing
E - Washer W- Bushing
F - Ball Bearing X - Thin Thrust Plate
G - Motor Case
IMPORTANT: Avoid damage! Do not drop or damage mo-
H - Locating Sleeve (2 used) tor valve plate when removing motor assembly. Do not nick
or scratch lapped or machined surfaces of the valve plate or
I - Motor Shaft cylinder block components. The slightest damage can cause
J - Center Valve Block Assembly poor performance.

K - Locating Pin 1. Remove two cap screws (A). (Fig. 55)

L - Motor Valve Plate IMPORTANT: Avoid damage! Keep pistons (S) matched with
M - Snap Ring bore of cylinder block (P). Do not interchange motor pistons
and valve plate (L) with pump pistons and valve plate. Pistons
N - Washer and cylinder blocks are a matched set.
O - Spring 2. Remove cylinder block assembly.
P - Cylinder Block
NOTE: Motor rotating components must be replaced as a
Q - Shim set.
R - Piston Spring
29
Hydrostatic Transmission Motor Disassembly and Assembly (2WD) (continued)
3. Inspect rotating components: NOTE: Apply silicon sealant to outer edge of new seal cap.
Install seal cap until cap is approximately 4 mm (5/32 in.) be-
NOTE: Scoring is fine scratches or grooves cut into the highly low surface of motor case.
machined surface. When the scratches can be detected by feel
using a lead pencil or fingernail, the part must be replaced. 11. Assemble parts in reverse order of removal.

4. Check valve plate and cylinder block for grooves, scor- NOTE: Use petroleum jelly to hold valve plate in position.
ing, discoloration or pitting. • Put motor valve plate (L) on center valve block. Make sure
bronze surface is away from valve block and notch in valve
5. Check for free movement of pistons in cylinder bore. plate fits on locating pin of valve block.
6. Check pistons for flat areas, scoring or discoloration.
IMPORTANT: Avoid damage! Apply clean hydraulic oil to all
7. Thrust bearing (V) must rotate freely. (Fig. 55) mating surfaces.
NOTE: Thin thrust plate (X), bushing (W) and motor case (G) IMPORTANT: Avoid damage! Pump and motor valve plates
must be replaced as a set. (Fig. 55) are not interchangeable. The pump valve plate has two lead-
8. Inspect thin thrust washer for wear or damage. Replace ing grooves into two of the slotted ports. The motor valve
as necessary. plate (L) has no leading grooves.

IMPORTANT: Avoid damage! Do not damage ball bearing NOTE: Motor case will seem springy because the springs in-
(F) when removing seal cap (B). side the cylinder block are being compressed.

9. Remove seal cap (B) and snap ring (C) to remove shaft
assembly components.
10. Inspect bushing (W), thrust bearing (V) and shaft (I) for
wear or damage. Replace if necessary. (Fig. 55)

30
 Tuff Torq K92 Hydrostatic Transaxle
Hydrostatic Transmission Motor Disassembly and Assembly (4WD)

Fig. 56, Hydrostatic Transmission Motor Disassembly (4WD)

A - Cap Screw (2 pieces) R - Gasket

B - Snap Ring S - Thick Thrust Plate
C - Snap Ring T - Thrust Bearing
D - Ball Bearing U - Bushing
E - Motor Case V - Thin Thrust Plate
F - Locating Sleeve (2 used) 1. Remove 4WD gear box assembly. (See “4WD Output
Disassembly and Assembly” on page 24.)
G - Motor Shaft
H - Center Valve Block Assembly IMPORTANT: Avoid damage! Do not drop or damage mo-
tor valve plate when removing motor assembly. Do not nick
I - Locating Pin or scratch lapped or machined surfaces of the valve plate or
J - Motor Valve Plate cylinder block components. The slightest damage can cause
poor performance.
K - Snap Ring
2. Remove two cap screws (A). (Fig. 56)
L - Washer
IMPORTANT: Avoid damage! Keep pistons (Q) matched with
M - Spring
bore of cylinder block (N). Do not interchange motor pistons
N - Cylinder Block and valve plate (J) with pump pistons and valve plate. Pistons
and cylinder blocks are a matched set.
O - Shim
3. Remove cylinder block assembly.
P - Piston Spring
Q - Piston NOTE: Motor rotating components must be replaced as a
set.
31
Hydrostatic Transmission Motor Disassembly and Assembly (4WD) (continued)
4. Inspect rotating components: 10. Remove snap ring (B) to remove shaft assembly compo-
nents.
NOTE: Scoring is fine scratches or grooves cut into the highly
machined surface. When the scratches can be detected by feel 11. Inspect bushing (U), thrust bearing (T) and shaft (G) for
using a lead pencil or fingernail, the part must be replaced. wear or damage. Replace if necessary. (Fig. 56)

5. Check valve plate and cylinder block for grooves, scor- IMPORTANT: Avoid damage! Apply clean hydraulic oil to all
ing, discoloration or pitting. mating surfaces.
6. Check for free movement of pistons in cylinder bore. 12. Assemble parts in reverse order of removal.
7. Check pistons for flat areas, scoring or discoloration. NOTE: Use petroleum jelly to hold valve plate in position.
8. Thrust bearing (T) must rotate freely. (Fig. 56)
• Put motor valve plate (J) on center valve block. Make
NOTE: Thin thrust plate (V), bushing (U) and motor case (E) sure bronze surface is away from valve block and notch
must be replaced as a set. (Fig. 56) in valve plate fits on locating pin of valve block.

9. Inspect thin thrust plate (V) for wear or damage. Re- IMPORTANT: Avoid damage! Pump and motor valve plates
place as necessary. are not interchangeable. The pump valve plate has two lead-
ing grooves into two of the slotted ports. The motor valve
IMPORTANT: Avoid damage! Do not damage ball bearing plate (J) has no leading grooves.
(D) when removing snap ring (B).
NOTE: Motor case will seem springy because the springs in-
side the cylinder block are being compressed.

32
 Tuff Torq K92 Hydrostatic Transaxle
Center Valve Block Disassembly and Assembly

Fig. 57, Center Valve Block Disassembly

A - Holder K - Top Plug

B - Spring L - O-ring
C - Ball M - O-ring
D - Push Pin N - Washer
E - O-ring O - Shim (0.5)
F - Seal P - Shim (0.2)
G - O-ring Q - Spring
H - Back-up Ring R - Charge Pressure Relief Valve Plunger
I - O-ring S - Reverse Check Valve
J - Forward Check Valve T - Seat

33
Center Valve Block Disassembly and Assembly (continued)
U - Center Valve Block 12. Inspect valve plate for grooves, scoring, discoloration or
pitting.
V - Needle Bearing (2 used)
W- Locating Pin (2 used) IMPORTANT: Avoid damage! Pump and motor valve plates
are not interchangeable. The pump valve plate has two lead-
X - Pump Valve Plate ing grooves into two of the slotted ports. The motor valve
Y - Anti-Cavitation Valve Body plate has no leading grooves.

Z - Backup Ring 13. Put pump valve plate on center valve block. Make sure
bronze surface is away from valve block and notch in
AA- O-ring valve plate fits on locating pin of valve block.
AB- Ball
NOTE: Use petroleum jelly to hold valve plate in position.
AC- Ball Holder
14. Remove plug to inspect charge pressure relief valve
AD- Spring parts.
AE- Retainer 15. Check plunger for nicks, wear or damage.
AF- Motor Valve Plate 16. Inspect plunger seat in center valve block. Remove any
obstructions and replace center valve block if seat is
NOTE: Remove motor assembly if necessary to inspect nee- worn or damaged.
dle bearing. (See “Hydrostatic Transmission Motor Removal:”
on page 28.) Hydrostatic Transmission Motor Installation
1. Remove and inspect directional check valves.
NOTE: Replace retaining ring (D) if ring is distorted during
removal.
IMPORTANT: Avoid damage! The reverse check valve must
be installed in the left port. The check valve can be identified
by a small orifice drilled into a land between the two sets of
valve passageways.
2. Replace locator pins if missing or damaged.
3. Inspect needle bearings for wear or damage. If bearings
are replaced, install new bearings with the stamped end
away from center valve block.
4. Push bearings into bore until end of bearing is approxi-
mately 3 mm (7/64 in.) above the surface of the valve
block.
5. Inspect anti-cavitation valve assemblies.

NOTE: Screens may be located in bores of transaxle case.

6. Check suction screens for blockage.
7. Carefully pull anti-cavitation valve body from center
valve block so as not to lose parts.
8. Replace parts as necessary.
9. Apply oil to O-rings and push assembly to bottom of
bore.
10. Inspect center valve block where charge pump contacts Fig. 58, Hydrostatic (2WD) Motor
block for scoring. 1. Secure motor housing assembly (A) and gasket (F) to
11. Replace center valve block if necessary. center valve block (B) with (2) lower capscrews (G). In-
stall ball bearing (C) and bevel input pinion (E) — secure
NOTE: Scoring is fine scratches or grooves cut into the highly with retaining ring (D).
machined surface. When the scratches can be detected by feel
using a lead pencil or fingernail, the part must be replaced.

34
 Tuff Torq K92 Hydrostatic Transaxle
Hydrostatic Transmission Installation
1. Install gasket (C). (Fig. 59)
IMPORTANT: Avoid damage! Do not drop or damage pump
valve plate when removing center valve block assembly. Do 2. Install center valve block (B) and motor assembly to
not nick or scratch lapped or machined surfaces of the valve transaxle housing and secure with cap screws (A).
plates or cylinder block components. The slightest damage (Fig. 59)
can cause poor performance.
• Tighten cap screws (A) to 39 N•m (29 lb-ft).
3. Install charge pump. (See “Charge Pump Removal and
Installation” on page 2)

Fig. 59, Hydrostatic, 2WD (4WD similar) Motor Install

Hydrostatic Pump Inspection

Fig. 60, Hydrostatic Pump Disassembly

35
Hydrostatic Pump Inspection (continued) 5. Remove PTO idler shaft assembly (C), snap ring (E), PTO
gear (D) (or rear drive gear set).
A - Washers
B - Piston Spring (7 used)
C - Snap Ring
D - Cylinder Block
E - Washer
F - Spring
G - Piston (7 used)
H - Thick Thrust Plate
I - Thrust Bearing
J - Thin Thrust Plate

IMPORTANT: Avoid damage! Keep pistons matched with

bore of cylinder block. Do not interchange motor pistons and
valve plate with pump pistons and valve plate. Pistons and
cylinder blocks are a matched set.
1. Spring is compressed. Apply an external force to com-
press spring farther before removing snap ring. Then
slowly remove external force.
2. Remove parts from transaxle as necessary. Fig. 61,Without Rear PTO Option

NOTE: Pump rotating components must be replaced as a

set. Thin thrust plate must be replaced as a set with the pump
swash plate and bushing.
3. Check cylinder block for grooves, scoring, discoloration
or pitting.

NOTE: Scoring is fine scratches or grooves cut into the highly

machined surface. When the scratches can be detected by feel
using a lead pencil or fingernail, the part must be replaced.
4. Check for free movement of pistons in cylinder bores.
5. Check pistons for flat areas, scoring or discoloration.
Thrust bearing must rotate freely.
For inspection of pump valve plate, refer to “Center Valve
Block Disassembly and Assembly:” on page 33.

Transaxle Disassembly
1. Remove control arm damper. (See “Control Arm and Fig. 62,With Rear PTO Option
Damper Removal and Installation” on page 1.)
6. Remove PTO brake shoe (B) and clutch (A). (See “PTO
2. Remove hydrostatic transmission and pump. (See “Hy- Brake Removal and Installation” on page 6.)
drostatic Transmission 2WD and 4WD” on page 35.)
7. Remove large snap ring (H) and input shaft assembly.
3. Remove axle housings. (See “Rear Axle Assembly Re-
moval and Installation” on page 41, and See “Rear Axle 8. Remove large snap ring (L), small snap rings (G and K)
Assembly - Disassembly and Assembly” on page 42.) washers (M and J), and ball bearing (I) from input shaft
(F). (Fig. 63)
4. Remove brakes. (See “Brakes Removal and Installation”
page 43.)

36
 Tuff Torq K92 Hydrostatic Transaxle
Transaxle Disassembly (continued)

F - Input Shaft
G - Snap Ring
H - Snap Ring
I - Ball Bearing
J - Washer
K - Snap Ring
L - Snap Ring
M - Washer

Fig. 63,Transaxle Input Shaft Disassembly

9. Lay transaxle on left side and remove sixteen (16) cap IMPORTANT: Avoid damage! Bearing, washer and differen-
screws (N) attaching right cover assembly (O). tial pinion located on top of differential assembly are loose.
Do not drop or lose parts.

Fig. 65, Final Pinon Gear

11. Lift final gear and differential assembly and differential
lock shaft from transaxle case together as an assembly.
Fig. 64, Right Transaxle Cover 12. Remove final pinion shaft assembly. (Fig. 65)
10. Remove final pinion shaft ball bearing. Bearing may
remain in cover assembly.

37
Transaxle (Right Cover) Disassembly and Assembly

Fig. 66,Transaxle (Right Cover) Disassembly

A - Swash Plate Bearing Q - Fulcrum Cap Screw

B - Washer 1. Remove nut (H), washer (I), and snap ring (F). (Fig. 66)
C - Bushing 2. Pull swash plate from cover (E).
D - Spring NOTE: Pump swash plate, bushing, and thin thrust plate
E - Cover must be replaced as a set.

F - Snap Ring 3. Inspect transaxle cover components.

G - Washer 4. Check bushing, bearing and swash plate contact sur-
faces for wear or damage. Replace as necessary.
H - Cap Screw
5. Inspect O-rings on swash plate and eccentric adjust
I - Washer fulcrum for cuts or damage.
J - Control Arm 6. Install spring so legs are crossed and each leg of spring
K - Nut fits into a groove of the fulcrum cap screw.
L - Washer 7. If swash plate bearing was removed, install new bearing
until end of bearing is even with the inside surface of
M - Pivot Stud the cover.
N - O-ring 8. Put petroleum jelly on all O-rings. Install swash plate
O - Eccentric Adjust Fulcrum assembly and remaining components.
P - Swash Plate NOTE: Use medium strength thread lock and sealer.

38
 Tuff Torq K92 Hydrostatic Transaxle
Inspection of Transaxle Case

Fig. 67, Front PTO Shaft Port Fig. 69, PTO Brake Pin Port, Swash Plate Bearing, and Vent Cap

1. Remove front PTO shaft seal (B). (Fig. 67) 7. Inspect PTO brake pin sleeve (E) for scoring or damage.
Replace if necessary.
2. Inspect needle bearing (A) for wear or damage. Remove
if necessary. Install new needle bearing from inside case 8. Push sleeve out from inside of case.
with bearing identification marks toward the inside of
9. Install new sleeve into case until flange of sleeve is tight
the case. Push bearing tight against shoulder in bore.
against case.
3. Install new seal with the open, spring side towards the
10. Inspect swash plate bearing (G) for wear or damage.
inside of the case.
Replace if necessary.
4. Push seal against shoulder in bore.
11. Install new bearing using a disk driver. Push bearing to
bottom of bore.
12. Inspect vent cap (F) for damage or obstructions. Replace
as necessary.
Transaxle Assembly:

Fig. 68, Differential Shaft Port

5. Replace differential lock shaft seal (C). (Fig. 68)

NOTE: Differential lock plate (D) may have to be removed to

install new seal.
6. Install new seal with the open, spring side towards
inside of case. Push seal tight against bottom of bore. Fig. 70, Final Pinon Gear

1. Apply clean hydraulic oil to all internal components.

2. Install final pinion shaft assembly into transaxle case
with bevel gear end in first.

39
 IMPORTANT: Avoid damage! Bearing and washer on top of
differential assembly are loose. Do not drop or lose parts.
3. Put fork of differential lock shaft into groove of collar on
differential assembly. Install differential assembly and
differential lock shaft together into transaxle case.
4. Install ball bearing.

Fig. 72,Without Rear PTO Option, Assembly

Fig. 71,Transaxle Right Cover Assembly

5. Apply a bead of silicon sealant to mating surface of

transaxle case.
6. Carefully lower right transaxle cover assembly (B) onto
case while making sure bearings and shafts fit into
bores properly. Make sure washer on swash plate does
not fall out of position. Secure with sixteen (16) cap
screws (A), and tighten to specification below. (Fig. 71)
Transaxle Case Cap Screw Torque Specifications:
• Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
• New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
7. Assemble bearing, washers and snap rings on input
shaft. Fig. 73,With Rear PTO Option, Assembly
8. Install input shaft assembly and large snap ring.

40
 Tuff Torq K92 Hydrostatic Transaxle
9. Install PTO brake shoe (D) and PTO clutch assembly (C). 13. Install axle housings. (Fig. 74)
(See “PTO Brake Removal and Installation” on page 6.)
14. Install hydrostatic transmission and pump.
(Fig. 72)
15. Install control arm damper. (See “Control Arm and
10. Install PTO idler shaft assembly (E), PTO gear (F) (or rear
Damper Removal and Installation” on page 1)
PTO gear on rear PTO option units), and snap ring (G).
11. Install PTO drive train. (See “PTO Drive Train (Mid and
Rear PTO) Removal and Installation” on page 11.)
12. Install brakes. (See “Brakes Removal and Installation” on
page 43.)

Rear Axle Assembly Removal and Installation

Fig. 74, Axle Disassembly

A - Shaft IMPORTANT: Note position of two locator bushings (J) when

removing axle housing.
B - Snap Ring
1. Remove six cap screws (I) holding axle housing to
C - Sleeve
transaxle housing, and remove axle assembly. (Fig. 74)
D - Seal
2. Clean axle housing and transaxle mating surfaces. Apply
E - Ball Bearing a bead of silicon sealant to mating surface.
F - Snap Ring 3. Repeat for other side if necessary. Installation is done in
the reverse order of removal.
G - Axle Housing
H - Bushing (2 used)
I - Cap Screw (6 used)
J - Washer

41
Rear Axle Assembly - Disassembly and Assembly

Fig. 76, Rear Axle Assembly

Fig. 75, Rear Axle Disassembly

9. Install axle shaft assembly into axle housing using a

1. Remove large snap ring (B) from groove of axle housing press. Press shaft only until a rapid increase in pressure
(G). (Fig. 74) is noticed.
2. Use a press to remove axle shaft (A) from axle housing
(G). (Fig. 75)
3. Remove remaining snap ring to remove axle shaft com-
ponents.
4. Inspect axle shaft and housing for wear or damage.
Replace parts as necessary.
5. Inspect bearing for smooth rotation. Replace if neces-
sary.

NOTE: Ball bearing is not pressed into housing. When placed

in axle housing it may be loose. A clearance up to 0.38 mm
(0.015 in.) is normal.
6. Install bearing, seal and snap ring into axle housing. Put Fig. 77, Rear Axle Cut-away
spring-side of seal into housing first.
7. Apply petroleum jelly to lips of seal and inner diameter
of sleeve. 10. Install washer (E) and snap ring (C) on axle shaft. (Fig. 77)
11. Use a piece of pipe (D) with a minimum inside diameter
of 31 mm (1-3/16 in.), maximum outer diameter of 43
8. Install snap ring, washer and sleeve on axle shaft. Use mm (1-11/16 in.) and approximately 330 mm (13 in.)
a piece of pipe with a minimum inside diameter of 31 long to install snap ring.
mm (1- 3/16 in.) to push sleeve and washer tight against
shoulder of shaft. IMPORTANT: Avoid damage! Do not use excessive force to
install axle shaft. Axle housing may be cracked or damaged if
IMPORTANT: Avoid damage! Do not use excessive force to too much force is used.
install axle shaft. Axle housing may be cracked or damaged if
too much force is used.

42
 Tuff Torq K92 Hydrostatic Transaxle
Brakes Removal and Installation

Fig. 78, Brake Disassembly

A - Snap Ring Q - Cam Lever

B - Brake Actuator Plate R - Brake Cover
C - Friction Plate S - Cap Screw
D - Steel Plate
E - Steel Ball 1. Inspect components on brake cover (R). Replace as nec-
essary. Apply petroleum jelly to O-ring. (Fig. 78)
F - Clevis Pin
2. Inspect plates for wear or spline damage. If groove pat-
G - Washer
tern in friction plates is no longer visible, replace plates.
H - Spring Lock Pin
3. Apply petroleum jelly to balls (E) and install balls in
I - O-ring cover.
J - Interlock Plate 4. Install steel plates (D) and friction plates (C) alternately
beginning with a steel plate.
K - Cotter Pin
5. Apply a bead of silicon sealant to brake cover mating
L - Washer
surface of transaxle case.
M - Rod
6. Install brake actuator plate (B) and brake cover assembly
N - Adjustment Nut (R).
O - Nut Brake Cover Cap Screw Torque Specifications:
P - Rod Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
43
Hydrostatic Flow Diagram Check Points

PTO Electrical Engagement Solenoid

Fig. 79, Check Points Rear PTO

Relief/Check/Tow Valve (Forward) Implement Relief Valve

Check/Tow Valve (Reverse)

Charge Pressure Control Valve

Charge Pressure Test Port

Anti–Cavitation Screen

Anti–Cavitation Check Valve

Pressure Reduction Valve

Fig. 80, Check Points Charge Pump/Center Valve

44
Tuff Torq K92 Hydrostatic Transaxle

45
Troubleshooting Guides
Note: If your specific problem and/or solution is not listed
below, consult a qualified Tuff Torq Disstibator.

Hydrostatic Transmission Problems

Machine will not move on its own power Erratic speed
u Free-wheeling linkage set for push or partially set
u Free-wheeling linkage set for push or partially set
u Control pedal linkage bent, binding or disconnected
u Linkage damper (shock absorber) failed
u Directional control valves leaking or stuck down
u Control pedal linkage bent, binding or disconnected
u Brakes set or not releasing
u Brakes set or not releasing
u Anti-cavitation valves leaking or stuck open
u Directional control valves leaking or stuck down
u Charge pump scored or worn
u Drive shaft not turning pump input shaft or charge
u Pump or motor valve plates scored or worn
pump key sheared
u Charge pressure relief valve leaking. Seat valve or
u Anti-cavitation valves leaking or stuck open
spring damaged
u Charge pump scored or worn
u Drive shaft not turning pump input shaft or charge
u Pump or motor valve plates scored or worn
pump key sheared
u Filter plugged or suction side air leak. Check filter,
charge pump or case seal
Machine will not move–Wheels locked up u Charge pressure relief valve leaking. Seat valve or
u Brakes set or not releasing spring damaged
u Swash plate control shaft or bushing worn
u Engine performance is poor or not operating or set at
Will not move in one direction
correct operating speeds. See Engine diagnosis
u Free-wheeling linkage set for push or partially set
u Control pedal linkage bent, binding or disconnected Machine will not stop
u Directional control valves leaking or stuck down
u Directional valve in wrong location u Free-wheeling linkage set for push or partially set
u Anti-cavitation valves leaking or stuck open u Control pedal linkage bent, binding or disconnected
u Pump or motor valve plates scored or worn u Brakes set or not releasing
u Neutral adjustment is not correct
u Anti-cavitation valves leaking or stuck open
Too aggressive in reverse u Swash plate control shaft or bushing worn
u Free-wheeling linkage set for push or partially set
u Linkage damper (shock absorber) failed Transmission operating hot
u Directional control valves leaking or stuck down u Free-wheeling linkage set for push or partially set
u Pump or motor valve plates scored or worn u Control pedal linkage bent, binding or disconnected
u Brakes set or not releasing. See Brakes section
u Neutral adjustment is not correct
Slow forward under load, or speed drops u Oil cooler may be plugged with debris
when load is applied u Directional control valves leaking or stuck down
u Forward pedal height needs to be adjusted u Anti-cavitation valves leaking or stuck open
u Free-wheeling linkage set for push or partially set u Charge pump scored or worn
u Control pedal linkage bent, binding or disconnected u Pump or motor valve plates scored or worn
u Directional control valves leaking or stuck down
u Drive shaft not turning pump input shaft or charge Hydraulic noise
pump key sheared u Free-wheeling linkage set for push or partially set
u Anti-cavitation valves leaking or stuck open u Brakes set or not releasing. See Brakes section
u Directional valve in wrong location u Neutral adjustment is not correct
u Charge pump scored or worn u Drive shaft not turning pump input shaft or charge
u Pump or motor valve plates scored or worn pump key sheared
u Filter plugged or suction side air leak. Check filter, u Directional control valves leaking or stuck down
charge pump or case seal u Anti-cavitation valves leaking or stuck open
u Engine performance is poor or not operating or set at u Charge pump scored or worn
correct operating speeds

46
Troubleshooting Guides

Hydrostatic Transmission Problems (continued)

Hydraulic noise (continued) PTO will not stay engaged (continued)
u Pump or motor valve plates scored or worn u Low charge pump output
u Filter plugged or suction side air leak. Check filter, u PTO pressure control valve faulty
charge pump or case seal
u Charge pressure relief valve leaking. Seat valve or Gear or bearing noise with PTO engaged
spring damaged
u Swash plate control shaft or bushing worn u PTO brake is not releasing. Check brake piston, O-
rings
u PTO brake springs faulty
Gear noise, dependent on speed, direction
of travel or during a turn PTO shaft slows down
u Go through procedures in “Hydrostatic Transmission u Excessive load on PTO output. Remove load
Test” for additional tests u Use higher engine rpm. Check engine performance
u Brakes set or not releasing. See Brakes section u PTO lube reduction valve orifice plugged
u Drive shaft not turning pump input shaft or charge u Low charge pump output
pump key sheared u PTO pressure control valve faulty
u Charge pump scored or worn u PTO clutch piston leaking, input shaft seal leaking or
u Pump or motor valve plates scored or worn clutch disk worn
u Filter plugged or suction side air leak. Check filter,
charge pump or case seal PTO Shaft will not stop, or slow to stop
u Check engagement solenoid circuit
Mid PTO Engagement Problems u
u
Engagement valve installed incorrectly
PTO brake is not releasing. Check brake piston, O-
rings
PTO will not engage u Excessive load on PTO output. Remove load
u Check engagement solenoid circuit u PTO brake springs faulty
u PTO switch not working
u PTO lube reduction valve orifice plugged
u Engagement valve installed incorrectly Transaxle Engagement Problems
u PTO pressure control valve faulty
u PTO clutch piston leaking, input shaft seal leaking or Hydraulic transmission complaint
clutch disk worn
u Brakes are applied or mis-adjusted
u Low charge pump output
u PTO shaft, gear or bearing failure
Rear drive wheels are locked up; will not
Engine stalls when PTO is engaged move directional pins down
u Excessive load on PTO output. Remove load u Brakes are applied or mis-adjusted
u Use higher engine rpm. Check engine performance u Differential lock collar, pin or differential carrier fail-
u Hydraulic circuit in relief. Remove restriction or load ure
u PTO brake is not releasing. Check brake piston, O- u Check axle or differential gear failure
rings
u PTO shaft, gear or bearing failure Rear wheel free-wheel; no transaxle drive;
hydraulic control valve pins are up
PTO will not stay engaged u Check axle or differential gear failure
u Check engagement solenoid circuit u Differential lock collar, pin or differential carrier fail-
u Engagement valve installed incorrectly ure
u PTO clutch piston leaking, input shaft seal leaking or
clutch disk worn
47
Troubleshooting Guides

Transaxle Engagement Problems (continued)

Differential lock will not engage
u Differential lock linkage is mis-adjusted.
u Differential lock collar, pin or differential carrier fail-
ure

Differential lock will not disengage

u Brakes are applied or mis-adjusted
u Differential lock linkage is mis-adjusted
u Differential is engaged. Check adjustment and/or
repair differential lock
u Differential lock collar, pin or differential carrier fail-
ure

Transaxle Noise Problems

Ratcheting noise as machine moves
u Brakes are applied or mis-adjusted
u Differential lock linkage is mis-adjusted
u Differential is engaged. Check adjustment and/or
repair differential lock
u Differential lock collar, pin or differential carrier fail-
ure
u Check axle or differential gear failure

Ratcheting noise as machine turns

u Differential lock linkage is mis-adjusted
u Differential is engaged. Check adjustment and/or
repair differential lock
u Differential lock collar, pin or differential carrier fail-
ure
u Check axle or differential gear failure

48