How to use this file...(Installation Instruction Sheets) ————————————————————————————————————————————––– Instructions for Print Vendors (Paper Manuals) Paper: * Finish Size is 8-1/2 x 11 * Body—50 lbs brilliant white offset or equivalent. Press: * Body—1-color, 2-sided Bindery: * If document is 1 or 2 pages, run as 8-1/2 x 11 sheets. * If document is 3 or 4 pages, and can be run as 2 sided 11 x 17 -- then fold to 8-12 - 11. * If document is MORE than 4 pages, run as 8-1/2 x 11 sheets with UL Corner Stitch. COVERS: * This document is a self-covered piece. • Check the last page of the document for the individual document number (a TP 200-XXXX-XX-XX-SMA number). BODY: * REMEMBER: ODD number pages are ALWAYS right hand pages, and EVEN number are ALWAYS left hand pages. General: * This instruction page is NOT part of the document and must NOT be printed. • Pages labeled with the text “THIS PAGE INTENTIONALLY BLANK” are placement pages ONLY, and should NOT be printed. ————————————————————————————————————————————––– THIS PAGE INTENTIONALLY BLANK Front Axle Support & PTO Repair Kit Installation Instructions Part No. 1687103 For Legacy / 2000 / 2900 Series Garden Tractors 8 Kit Contents: 7 Ref 1 2 3 4 5 6 7 8 6 1 2 2 3 4 3 5 Part No. 1960223 932577 1917372 1917356 1727823 930671 1727812 1727826 Qty. 4 2 4 4 1 1 1 1 Description CARRIAGE BOLT, 5/16-18 x 1-1/4 SNAP RING NUT, Hex, 5/16-18 WASHER, Lock, 5/16 SUPPORT PLATE KEY SHAFT, PTO AXLE SUPPORT ASSEMBLY 4 Figure 1. Contents This kit can be used to repair damage to the front axle bushing, PTO shaft, and wear surfaces associated with the front axle and PTO system on Legacy / 2000 / 2900 Series tractors. A INSTALLATION Direction to release tension on belt WARNING Before beginning any service work turn off the PTO, set the parking brake, turn off the ignition, and disconnect the spark plug wire(s). B D Remove Front Axle & PTO Components C 1. Park the tractor on a level surface. 2. Place blocks in front of and behind the rear wheels. Figure 2. Remove PTO Belt A. PTO Clutch Assembly C. Lower PTO Pulley B. PTO Belts D. Idler Pulley 3. Turn the ignition key switch to the OFF position, remove the key, set the parking brake, and turn the PTO switch off. 4. Disconnect the negative (-) battery cable. 5. Disconnect spark plug wires to prevent the possibility of accidental starting. 6. Push the idler pulley (D, Figure 2) in to release tension on the PTO belts. Remove the PTO belts. 1 Installation Instructions A. B. C. D. E. F. G. H. I. PTO Repair Kit Spline Cover (Retain) Snap Ring (Discard) Washer (Retain) Pulley (Retain) Bearing & Locking Collar (Retain) PTO Shaft & Key (Discard) Lockwasher & Nut (Discard) Carriage Bolt (Discard) Retainer (Discard) B E G H F E D C B I A Retainer used during initial assembly only. Discard during servicing. G Figure 3. Remove PTO Components NOTE: For steps 7-11 refer to Figure 3 for information on which parts to retain and which parts to discard. B C A 7. Remove the spline cover (A, Figure 3), both snap rings (B), the washer (C), and PTO pulley (D). D C 8. Loosen the locking collars on the bearings (E) by turning them in the opposite direction of shaft rotation. B 9. Remove and discard the hardware securing the bearings (G, H). F 10. Remove the PTO shaft and key (F). E 11. Elevate the front of the tractor and support the frame with jack stands so that the axle assembly can be removed. 12. Support the front axle assembly. Using a drift and hammer, remove the axle pivot spacer (D, Figure 4). CAUTION: When the spacer is removed, the front axle will drop. Keep hands and feet clear of the axle and spacer area. Discard the spacer (D). G H G Figure 4. Front Axle Removal A. Frame E. Axle Tube Spacers B. Washer F. Flange Nut C. Capscrew G. Grease Fitting D. Axle Pivot Spacer H. Axle 13. Support the axle and remove the capscrews (C, Figure 4), washers (B), and flange nuts (F) that are holding the axle (H) in the frame (A). 14. Remove and retain the axle tube spacers (E) then lower the axle down out of the frame. 2 Installation Instructions PTO Repair Kit A. B. C. D. E. F. G. H. I. J. Tighten Bearing Locking Collar in Direction of Shaft Rotation. Spline Cover Snap Ring (New) Washer Pulley Bearing & Locking Collar PTO Shaft & Key (New) 5/16 Lockwasher & Nut (New) Carriage Bolt, 5/16-18 x 1-1/4 (New) Axle Support Assembly (New) Support Plate (New) J B E G H Tighten Bearing Locking Collar in Direction of Shaft Rotation. F E D C B I A G Figure 5. Install PTO Components B C A Install Front Axle and New PTO Components 1. Insert the four new 5/16-18 x 1-1/4 carriage bolts (H, Figure 5) into the frame. These are used to secure the front and back PTO bearings. Insert the bolts through the frame and secure in place by wrapping half the length of the threads with a thin strip of duck tape. This tape will retain the bolts while the axle is installed. It is important that only half the threads be covered so as to allow the nut and lockwasher to be started, and ultimately retain the bolt. C B E D 2. Insert the axle (F, Figure 6) and spacers (D) into the frame. Secure with the original capscrews (C), washers (B), and flange nuts (E). Torque the flange nuts (E) to 75 ft.lbs. F 3. Insert the axle support assembly (I, Figure 5) into the frame. Figure 6. Front Axle Installation A. Frame D. Axle Tube Spacers B. Washer E. Flange Nut C. Capscrew F. Axle 4. Install the new PTO shaft (F), support plate (J), and bearings (E). Do not tighten the bearing locking collars at this time. Align all parts and secure with new lockwashers and nuts (G). 5. Install the PTO pulley (D), washer (C), and retaining rings (B). 6. Align all parts and secure the bearing locking collars (E). Tighten the collars in the direction of shaft rotation. 3 Installation Instructions PTO Repair Kit 7. Push the idler pulley (D, Figure 7) in to release tension and install the PTO belts. 8. Reconnect the spark plug wires and negative battery cable. A Direction to release tension on belt B D C Figure 7. Install PTO Belt A. PTO Clutch Assembly B. PTO Belts MANUFACTURING, INC. 500 N Spring Street / PO Box 997 Port Washington, WI 53074-0997 USA C. Lower PTO Pulley D. Idler Pulley Form No. 1727929-00 Rev. 1/2004 © 2004 Simplicity Manufacturing, Inc. All Rights Reserved TP 200-4173-00-SK-SMA
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