Cushman TURF-TRUCKSTER Service & Repair Manual page 109

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REASSEMBLY (See Figure 4I-13)
Lubricants to be added during reassembly are
specified in Section 11.
1. Install the input shaft through the main shaft rear
bearing bore.
2. Align and install the input shaft through the inter-
mediate bearing bore as far forward as possible.
3. Put approximately .5 oz. of clean grease in the
pocket of the main shaft.
4. Lubricate the main shaft bearing surface. Install
the main shaft into the driven gear.
5. Install the shift collar on the main shaft.
6. Install the driven gear, shift collar and main shaft
assembly through the opening in the top of the
housing in the same manner as removal was
done.
7. Move the main shaft forward to engage the input
shaft pilot bearing.
8. Align the input shaft intermediate bearing in the
bore of the housing. Use a rubber mallet to tap
the input shaft rearward in the bearing bore as far
as possible.
9. Install two pilot studs and install the front cover as
described in "Front Cover Reassembly."
10. Turn the differential assembly on the work bench
so that the main shaft is pointing upwards.
11. Lubricate and install the bronze thrust washer
over the machined shoulder of the main shaft
against the driven gear. Install the bearing collar
against the thrust washer.
12. Install the bearing retaining ring in the groove of
the housing.
13. Lubricate and install the main shaft bearing in the
bore of the housing and install the retaining ring
(beveled side up) in the groove of the housing.
14. Install the pinion drive gear spacer on the main
shaft.
15. Turn the differential assembly so that it is horizon-
tal on the work bench. Install the large driven gear
on the pinion shaft.
16. Install the flat washer and new locknut on the pin-
ion shaft. Only tighten the locknut to approximate-
ly 50 ft-lbs. (68 N.m) at this time.
17. Lubricate the bushings in each end of the cluster
gear with clean grease.
SECTION 4I. REAR AXLE
NOTE
18. Lubricate the jackshaft. Install the shaft through
the bore of the housing only far enough to support
one thrust washer. Retain the thrust washer on
the shaft next to the housing with grease.
19. Install and align the cluster gear in the housing
and push the jackshaft partially into the gear.
20. Lubricate the two front side cluster gear thrust
washers with grease and carefully slide and align
the two thrust washers between the housing and
front face of the cluster gear. Push the jackshaft
through until the groove in the shaft is visible in
the setscrew hole.
21. Install the small pinion drive gear on the main
shaft.
22. Put Loctite 243 (Textron P/N 2810300 or 2811163)
thread lock on the jack shaft setscrew and install
the jackshaft setscrew in the housing. Move the
shaft, if necessary, so that the setscrew will
engage the groove in the shaft. Center the oil
pickup tube between the pinion drive and driven
gears. Tighten the setscrew securely.
The oil pickup tube must not contact or rub on
either gear. There must be equal clearance.
23. Use a large wrench on the hub of the large driven
gear to hold the gear stationary. Tighten the lock-
nut to a torque of 200 to 225 ft-lbs. (270 to 305
N.m).
24. Install the oil baffle and main shaft washer on the
main shaft.
25. Install a new locknut. Tighten the locknut to a
torque of 64 to 74 ft-lbs. (87 to 100 N.m). Slide
the shift collar forward on the main shaft and use
a bar in the input drive yoke to hold the main shaft
while tighten the nut.
26. Rotate the input shaft in each gear ratio to check
operation. Transmission rotation must be smooth
with no binding or lockup.
27. Install two pilot studs opposite each other in the
threaded holes for the rear cover.
Vehicles with 4-cylinder (Suzuki 970) gasoline
engines have a 14.12:1 gear ratio hypoid and
have a spacer between the rear cover and hous-
ing. Install a new spacer (see Parts Catalog) for
these vehicles. Vehicles with other engines use
a 11.16:1 gear ratio hypoid and do not use this
spacer.
28. Coat the machined flange of the rear cover and
align and install the cover.
4I-11
DRIVE TRAIN
NOTE
NOTE
4I