Pinion Shaft Assembly; Removal - Troy-Bilt 7 HP Technical Manual

SECTION 5: PTO Power Unit Transmission
PTO HORSE MODEL
TECHNICAL MANUAL
Page 5-5 4/90
c. Lightly lubricate the new bear-
ings with #30 weight oil.
5. Insert the drive shaft (17) into
the front of the housing.
6. Install the bearing cup (20) on
the front bearing.
7. Place the front bearing cap
(14) over the bore opening and
seat it by tapping it with a mallet.
A gasket (16) should not be on the
bearing cap at this time. Hold the
bearing cap firmly in place with
one hand while you check the
drive shaft for end play by pulling
and pushing the drive shaft. Cor-
rect end play is between .005 and
.010 of an inch.
a. If there is less than .005 of an
inch play or if the end play is
between .005 and .010 of an inch,
then remove the bearing cap and
place a gasket (16) on the cap.
Check for end play again. If the
end play is correct, go to step 8.
b. If there is more than .010 of an
inch play, then remove the bearing
cap and shim (18) accordingly.
Test for end play again. If the end
play is correct, remove the bearing
cap and place a gasket (16) on the
cap. Then go to step 8.
8. Install the front bearing cap
and secure it with bolts (12) and
lockwashers (13). If lockwashers
are not available, apply a coating
of non-hardening gasket sealer to
the tip of the bolts.
9. Apply a layer of non-
hardening gasket sealer to the
outer sealing edge of the front
bearing cap oil seal (15). Install the
seal flush with the bearing cap.
10,; Apply a layer of non-
hardening gasket sealer to the
outer sealillg edge of the rear
drive shaft oil seal (11). Install the
seal and stop when you feel the
seal hit the snap ring.
11. Apply a heavy coating of
grease to the dog clutch (5),
including the groove in the outer
surface. Slide the dog clutch on
the drive shaft, making sure the
three "ears" point to the rear of the
transmission.
12. Align the keyway in the shaft
and the keyway in the dog clutch
and insert the key (10) all the way
forward.
13. Using snap ring pliers,
install the (external) snap ring (4)
that retains the dog clutch to
the drive shaft. The flat side of the
snap ring should face the rear of
the transmission. Although not
easy to observe, the snap ring has
a flat side and a rounded side.
14. Stick your finger in the
eccentric shaft assembly hole and
position the groove on the dog
clutch in the center of the hole.
15. Apply a thin coating of
grease to the socket head screw
(or ball bearing assembly on ear-
lier models) on the eccentric shaft
assembly and the shifting arm
(6-9). Then insert the assembly
into the hole. Hold the assembly
so that the socket head screw is at
12 o'clock.
16. Using your fingers, gently
turn the hex nut/bushing (6) until
the hex nut is snug against the
power unit housing.
Note:
The hex nut/bushing
should turn freely at all times until
the nut is against the housing.
Do not use force; you can damage
the eccentric shaft or socket head
screw. If necessary, back the nut
off a few turns and rotate the eccen-
tric shaft a fraction of a turn. Then
try to thread the nut inward again.
17. Make sure that you have
properly seated the screw head in
the clutch groove. Rotate the
eccentric shaft back and forth
while looking through the rear of
housing. The screw is properly
seated if the clutch moves back
and forth with each turn of the
eccentric shaft.
18. Tighten the hex nut/bushing
securely with a wrench.
19. Fill the dog clutch cavity with
grease. Stop where the housing
bore widens to accept the tiller
attachment sleeve.
20. Attach the Tines/PTa Clutch
Lever (2) and finger tighten the
bolt (1) that holds the lever.
21. Install the PTa power unit
housing cover. See the instruc-
tions in this section.
22. Install the drive shaft pulley
by reversing steps 5 and 6 of the
drive shaft removal instructions.
Pinion Shaft
Assembly
These instructions describe how
to service the pinion shaft assem-
bly. Before you can service the
pinion shaft assembly you must
first drain the transmission gear oil
and remove the PTa power unit
drive shaft assembly. See the drive
shaft removal instructions in this
section.
Use Figure 5-4 as a reference
for part locations in these
instructions.
Removal
1. Using a 3/16-inch punch and a
hammer, knock out the spirol roll
pins (1) from the pinion bearing
retaining plugs (2) on each side of
the housing.
2. Using pump pliers or screw-in
pullers, remove the pinion bearing
retaining plugs.
3. Cut and discard the a-ring (3)
from each retaining plug.
4. Remove the shims (4) from
either side of the housing.