Woods TS1680 Operator's Manual page 33

Disassemble Gearbox
1. Remove dipstick plug from top of gearbox and
siphon gear lube from housing.
2. Remove ten 10 mm cap screws (3) from around
input housing (19). Remove input shaft assembly
and housing.
3. Remove eight 10 mm cap screws (3) from each
side of gearbox housing. Remove cover (4) and
seal (2) from both sides of output shaft (1).
4. Remove shims (9) from both sides of output shaft
(1).
5. Support gearbox in a hand press and push on the
left side of output shaft (1) to remove right bearing
(5), shim (6) and gear (7a) from housing.
6. Support housing in vise in horizontal position.
7. Remove left bearing (5) and shim (6) by using a
punch and hammer from right side of housing.
Drive bearing out of housing.
8. Support housing in vise in a horizontal position.
9. The castle nut (8), cotter pin (25), and hub are
already removed with the crossbar. Remove the
protective seal (14), and oil seal (13).
10. Remove cotter pin (16), castle nut (17), gear (7a or
7b), and shim (10) from vertical output shaft (15).
11. Remove vertical output shaft (15) by using a punch
and hammer and tap on top to drive down.
12. Remove bottom bearing (12) by using a punch and
hammer from the top, outside the housing.
13. Support housing upside down and remove top
bearing (11) by using a punch and hammer from
the bottom side of the housing.
14. Remove cotter pin (16), castle nut (17), spacer
(24), gear (23 or 7b), and shim (10) from input shaft
(20).
15. Remove seal (21) from input housing (19).
16. Support input housing in a vise and remove
bearing (22) by using a punch and hammer. Drive
bearing out of housing.
17. Inspect gears for broken teeth and wear. Some
wear is normal and will show on loaded side.
Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
18. Inspect vertical and horizontal shafts for grooves,
nicks or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
19. Inspect housing and caps for cracks or other
damage.
Assemble Gearbox (Figure 15)
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
MAN0577 (6/29/2007)
(Figure 15)
2. Wash housing and all components thoroughly.
Select a clean area for gearbox assembly. Replace
all seals, bearings and gaskets. All parts must be
clean and lightly oiled before reassembly.
3. Insert both output bearings (11 & 12) in the
housing, using a round tube of the correct diameter
and a hand press.
4. Slide output shaft (15) through both bearings (11 &
12) until it rests against top bearing (11).
5. Slide shim (10) over output shaft (15).
6. Press gear (7a or 7b) over output shaft (15) and
secure with castle nut (17) and cotter pin (16).
7. Apply grease to lower seal lips (13) and press seal
(13) over output shaft (15), using a tube of the
correct diameter. Be sure not to damage seal lip.
8. Press in housing so that seal is recessed. Press
protective seal (14) until seated flush with housing.
Verify that the seal (13) is seated correctly.
9. Install seal (2) in cover (4) using a tube of the
correct diameter. Be sure not to damage seal.
10. Install cover (4) onto right side of housing using
eight 10 mm cap screws (3).
11. Press shim (9) and bearing (5) in right side of
gearbox housing using a round tube of the same
diameter and a hand press.
12. Place shim (6) and gear (7a) inside of gearbox
housing.
13. Insert output shaft (1) through opening in left side
of gearbox, gear (7a), shim (6), bearing (5) and
shim (9) on right side of housing.
14. Place second shim (6), bearing (5), and shim (9)
on left side of output shaft (1).
15. Place cover (4) over left end of output shaft (1) and
secure to housing using eight 10 mm cap screws
(3).
16. Place seal (2) over output shaft (1) and press into
cover (4) using a tube of the correct diameter.
17. Press bearing (22) into input housing (19), using a
round tube of the same diameter and a hand press.
18. Assemble bearing (18), shim (10), gear (7b or 23)
onto input shaft (20). Secure with spacer (24),
castle nut (17) and cotter pin (16).
19. Insert input shaft assembly into gearbox housing
and align teeth of the three gears.
20. Place input housing (19) over input shaft and
secure into position using cap screws (3).
21. Place seal (21) over input shaft on cover and press
into housing using a tube of the same diameter.
22. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
Dealer Service 33