5 Bevel Gear Drive

Table Of Contents SECTION CONTENTS

Description
Description................................................................................... 5-2

Preparation
Removal MFG. Nos. 990100 Thru 990500 Tractors.................... 5-2 Removal MFG. Nos. 990600 Thru 990900 Tractors.....................5-3 Removal 7000 Series, 7100 Series and Later ..............................5-3 Inspection and Cleaning ...............................................................5-5 Disassembly All Models................................................................5-6 Inspection, Cleaning and Repair...................................................5-7

Assembly
Replacing Bearings and Seals......................................................5-8 Assembly of Gears and Shafts .....................................................5-8

Installation
Installation.....................................................................................5-9

Lubrication
Lubrication ....................................................................................5-9

Bevel Gear Cross Section

Input and Output Cross section ..................................................5-10

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SECTION 5. BEVEL GEAR DRIVE

5 Bevel Gear Drive

Description DESCRIPTION
The bevel gear drive transmission houses a drive shaft, driven shaft and their respective bevel gears, bearings and seals. This assembly transfers the engine drive to the transmission through a drive pulley and V-belt arrangement. The basic difference between the earlier (Figure 1) and later (Figure 2) bevel gear drives is the drive pulley arrangement, shaft sizes, and bearings. 4. Support tractor under frame just ahead of bevel gear housing. 5. Disconnect brake linkage, clutch-brake rod and transmission shift rod. 6. Remove transmission drive belt and cap screws securing transmission to side plates. On the Sovereign Tractor it will be necessary to remove the variable speed pulleys. 7. Disconnect drive shaft before rolling transmission from tractor. 8. Roll transmission rearward from tractor. 9. Remove gear shaft flange from bevel gear shaft. 10. Remove cap screws holding bevel gear housing to frame, lift off housing. 11. Remove rope starter pulley. This is not on the Sovereign or 2110 Landlord Tractor. 12. Remove transmission drive pulley. 13. Remove PTO drive pulley. 14. Remove side plates.

PREPARATION
This section covers complete removal of the bevel gear drive for servicing. However, some servicing procedures can be accomplished by removing the housing cover. Major service requires removal.

Removal MFG. Nos. 990100 Thru 990500 Tractors. See Figure 1.

1. Remove seat assembly. 2. Remove dash assembly. 3. Remove top frame cover.

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5 Bevel Gear Drive

Preparation
Removal MFG. Nos. 990600 Thru 990900 Tractors
1. Remove drive unit, drive belt, and pulleys: a. Refer to Section 8 if tractor is equipped with 3speed or shuttle transmission. b. Refer to Section 14 if tractor is equipped with a hydrostatic transmission. 2. Refer to Section 6 for removal of Power Take-off, which has to be removed before the side plates can be removed from the bevel gear housing. Remove drive pulley and key (page 6-2). 3. See Figures 3 and 4. Remove the three cap screws (A) from each side plate. 4. Pull the side plates apart, separating them from the bevel gear housing, but leaving the linkage parts still assembled to each.

Removal 7000 Series, 7100 Series and Later

1. Remove drive unit, drive belt, and pulleys: a. Refer to Section 8 if tractor is equipped with 3speed or shuttle transmission. b. Refer to Section 14 if tractor is equipped with a hydrostatic transmission. 2. Refer to Section 6 for removal of Power Take-off, which has to be removed before the side plates can be removed from the bevel gear housing. Remove drive pulley and key. 3. See Figure 2a. Remove the cap screws from each side plate. 4. Pull the side plates apart, separating them from the bevel gear housing, but leaving the linkage parts still assembled to each.

Figure 2. Exploded View of the bevel Gear Drive (Mfg. Nos. 990653-1690232)

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5 Bevel Gear Drive

Preparation

Figure 2a. Exploded View of the bevel Gear Drive (Mfg. Nos. 1690233-Later)

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5 Bevel Gear Drive

Preparation
Inspection and Cleaning
1. Remove the shims (A, Figure 5) from the right side shaft. 2. Examine the housing in the areas of the cover gasket and oil seals for signs of oil seepage. If so, note the location for future attention. 3. Remove all dirt and grease from the exterior of the housing and shafts. Steam cleaning is preferable, but a water soluble grease solvent may be used. Brush solvent on thickly, let the solvent act for a time, and then hose it off with hot water. 4. Spin the driver shaft (C, Figure 5) several revolutions in both directions while applying light braking pressure to the driven shaft (B, Figure 5). Repeat this procedure, spinning the driven shaft. Note for future attention any noticeable binding, roughness, unevenness in the motion, or excessive backlash (lost motion) between the gears. The true backlash can only be checked once the shims and side plates are installed.

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5 Bevel Gear Drive

Preparation
Disassembly -- All Models
1. Remove drain plug (J, Figure 6) and drain fluid from housing. Then replace and tighten drain plug (J, Figure 6). If housing has filler plug with dipstick on top of housing, as illustrated in Figure 2 insert, remove filler plug during disassembly and assembly procedures. 2. Block the housing up on short pieces of wood on a bench, (Figure 6). 3. Remove the nut (E, Figure 6) from the short end of the driven shaft. 4. Remove the woodruff key (F, Figure 6). 5. Using a fine file, remove any burrs around the keyway. Do not remove any surface material. 6. Remove the spacer sleeve (G, Figure 6). 7. With a strip of fine abrasive cloth, polish the exposed short end of the shaft to remove any file marks. 8. Using a clean rag, remove all abrasive dust from the shaft, the seal, and the keyway. Spread a film of light oil over the entire short end of the shaft. 9. Remove the six cap screws (H, Figure 6). 10. Using a screwdriver, carefully pry off the cover (I, Figure 6). 11. Using a lead or rawhide hammer as a buck to back up the gear (A, Figure 7), drive the shaft from right to left as shown (B, Figure 7) through the gear to expose the key (C, Figure 7). You may find it easier to have the open end of the snap ring down over bolt. 12. Remove the key (C, Figure 7). 13. If it is present, disengage the retaining ring (D, Figure 7) from its groove and slide it over near the gear (A, Figure 7). 14. Stuff a clean rag into the housing under the driven shaft. Then use a fine file to remove any burrs from around the keyway and ring groove. Reduce all protrusions to shaft surface level, but do not remove any surface material. Do not use any abrasive. 15. Remove the rag, being careful not to spill any filings into the gears or bearings. 16. Pull the shaft (B, Figure 7) out of the housing with one hand, while holding the gear (A, Figure 7) with the other hand. 17. Remove the cap screw (E, Figure 7) and lift out the clamp plate (F, Figure 7). 18. Turn the housing over as shown in Figure 8.

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5 Bevel Gear Drive

Preparation
19. Place a piece of brass rod on the overhanging end of the key (B, Figure 8) and drive the key out of its keyway. Or use a side cutter to remove key. 20. Using a fine file, remove any burrs from around the keyway. Using a strip of abrasive cloth, polish the shaft to smooth the file marks. 21. With a clean cloth, clean grit from the shaft, the keyway, and around the seal. Spread a film of light oil over the entire exposed area of the shaft. 22. With a plastic mallet, drive the shaft downward until it begins to move freely. Be careful not to hit the seal with the mallet. 23. Turn the housing over and lift the shaft, gear, and ball bearing assembly out of the housing.

Inspection, Cleaning and Repair

1. After bearing is washed with solvent and lubricated. Hold the driver shaft with one hand and spin the outer race of the ball bearing with the other hand. Any binding or unevenness in the motion or perceptible side play of the outer race indicates the need for bearing replacement. 2. Examine the area of the driver shaft that serves as a journal of the needle bearing. Any scoring, galling, excessive wear, or discoloration due to overheating indicate the need for shaft and needle bearing replacement. 3. Examine the area of the driver shaft that turns in the oil seal. Any scratches or other surface defects indicate the need for shaft and oil seal replacement. 4. To disassemble the shaft from the gear and ball bearing for replacement of any of these items, proceed as follows: a. Lay the shaft on a wooden block. Drive the key at the end opposite the gear back into the keyway. An end of the key should hang over the end of the shaft to permit easy removal. b. With gear facing upward, grasp portion of driver shaft below bearing between thick lead jaws of a vise. The shaft key should be against a jaw to prevent shaft rotation in the next step. c. With a socket wrench, back out cap screw (A, Figure 9) and 1/4 inch. d. Remove shaft from vise. Grasp the gear only with a leather-gloved hand and strike head of cap screw (A, Figure 9) with a plastic mallet until cap screw bottoms out on gear. e. Remove cap screw (A, Figure 9) and washer(s). Then repeat step d using a piece of brass or plastic rod to drive shaft out of gear.

f. Remove both keys from the driver shaft. Holding the shaft with the bearing above to keep filings out of bearing, remove any burrs from keyway with a fine file. g. Use a clean rag to remove the filings and then apply a light coat of oil over the short end of the shaft. h. Reinstall the cap screw (A, Figure 9). Hold the bearing with a gloved hand and gently tap the cap screw with a plastic mallet to drive the shaft out of the bearing. 5. If initial inspection indicated fluid leaks around shafts, replace related seals. Pry seals out carefully; do not scratch or score the bore that the seal fits. 6. Inspect bore of shaft in housing assembly for wear. 7. Examine the needle bearings. To remove a damaged needle bearing, it is first necessary to remove the adjacent seal. Drive the bearing inward, using a smooth faced plug with a diameter slightly smaller than the bore. 8. Spin the inner race of the ball bearing in the housing. Any binding, unevenness in motion, or side play indicates the need for replacement of the ball bearing and adjacent seal. To remove the bearing, push it outward with a smooth faced plug slightly smaller than the bore. 9. Examine the driven shaft. Any evidence of scoring, galling, seizing, excessive wear, or discoloration due to overheating indicates the need for shaft, seal, and needle bearing replacement If the shaft is all right except for scratches in the area that runs in a seal, replace the shaft and the seal. 10. Examine both gears. If gears are worn or damaged or if initial spin tests indicated problems and bearing problems are not evident, replace both gears. 11. Remove all foreign material from housing gasket flange and the mating surfaces of the cover. Scrape surfaces until clean, but do not remove any surface material. 12. Thoroughly clean inside of housing with a grease solvent

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5 Bevel Gear Drive

Assembly ASSEMBLY
A cross section of the bevel gear assembly is shown on page 5-10. Viewing this prior will aid in an understanding of seal, shim, ring washer and key placement.

Replacing Bearings and Seals

1. Install the ball bearing for the output driven shaft into the housing. Use a driving plug and hammer to gently tap the bearing inward until it seats against the shoulder of the bore. The driving plug must be hollow with a rim that bears only against the outer race of the bearing. Do not drive or press against the inner race. 2. Install the related ball bearing onto the input driver shaft. Use a driving plug and hammer to gently tap the bearing until it seats against the shoulder of the shaft with the special washer and retaining ring . This driving plug should be hollow with a rim that bears only against the inner race. 3. Install the needle bearings into the housing with the flat side facing upward. Drive the bearing inward until it is flush with the bottom of the counter bore. Use a smooth faced driving plug about 1/8 larger in diameter than the bearing. 4. Install the seals into the housing with the spring element facing inward greasing sealing lips prior to installation. Seals should not be installed until shafts have been installed. Use a smooth faced plug with an outer diameter slightly smaller than the counter bore for the seal. When properly seated, the seals other than the one for the driven shaft ball bearing will be about flush with the housing surface, the seal for the ball bearing will be slightly below the flush point.

Assembly of Gears and Shafts

1. Install the woodruff key (A, Figure 10) in the gear end of the driver shaft (B, Figure 10) and, resting the gear (C, Figure 10), face down, tap the shaft downward with a plastic mallet until its hub is within a quarter of an inch of the ball bearing. 2. With the key in the outboard end of the shaft temporarily installed to prevent rotation, grasp the driver shaft between thick lead jaws or hardwood blocks in a vise. Replace the special washers and apply removable locktite to the Grade 8 capscrew (A, Figure 9), torque to 27-33 ft/lbs. drawing the gear down against the inner race of the ball bearing. 3. Remove the outboard key, clean the shaft, and cover shaft with a light film of oil. 4. Block the housing up, (Figure 11). 5. Install the driver shaft assembly (B, Figure 11) in the housing, pushing it gently downward from the inside 5-8

until the ball bearing enters its seat. Do not strike the gear. Use a plastic rod held at an angle against the outer race of the bearing. 6. Install the clamp plate (C, Figure 11) with the arch upward. Then install and tighten the cap screw (D, Figure 11) until the clamp plate bends downward and is tightly clamped to the housing wall. 7. Clean the driven shaft (F, Figure 11) and cover it with a light coat of oil. Then insert the large threaded end of the driven shaft into the housing through the needle bearing at the left side when the housing is viewed as shown in Figure 11. 8. Slip retaining ring (F, Figure 11) onto the shaft. It is difficult to slide shaft past or over the capscrew with the ring on. Then hold the gear (G, Figure 11) inside the housing while turning the shaft into the gear. When the slot appears, snap the retaining ring (F, Figure 11) into place.

5 Bevel Gear Drive

Assembly
9. Place woodruff key (H, Figure 11) in its keyway on the shaft. Use a hammer to tap key into place. 10. Align key to the keyway slot in gear (G, Figure 11). 11. Install the spacer (I, Figure 11) with the painted end outward on the short end of the driven shaft. Turn the spacer gently through the oil seal until it seats against the ball bearing. 12. Bore a 1-5/16 inch hole through a block of soft lumber, stand the housing with driven shaft (F, Figure 11) vertical and the outer end of sleeve (I, Figure 11) centered over the bored hole. Drive the shaft downward with a plastic mallet until the retaining ring contacts the face of the gear. 13. Test operation of the assembly by spinning first the driver shaft (B, Figure 11) and then the driven shaft (F, Figure 11). If the motion is not completely free, isolate the cause of the difficulty and correct it before proceeding further. 14. Lay a new gasket on the flange of the housing. Place the cover over the gasket and align the six screw holes in the housing, gasket and cover. Then install and tighten the six cap screws (H, Figure 6). 15. Use a lead hammer to back up the driver shaft (A, Figure 8) and a brass hammer to drive the key (B, Figure 8) into its keyway. For easy future removal, the key should overhang the end of the shaft by about 1/8 inch. 16. Install seals at this time. When installing seal (D, Figure 5) drive seal in until it contacts the outer race of the ball bearing. The seal is what maintains the ball bearing in its correct position. Once installed, stack shim pack (A, Figure 5) so that half the thickness of the thicker shim protrudes the bevel gear case housing machined surface. This insures the shim pack will compress when the side plate is installed.

INSTALLATION
Install bevel gear box in reverse order of removal. (Refer to removal procedures at beginning of this section.)

LUBRICATION
Fill bevel gear box with Simplicity multi-purpose hydraulic/transmission oil. Pour fluid slowly and check level often. Gearbox is full when level reaches top of filler pipe elbow (older models) or tip of filler plug dipstick (newer models).

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5 Bevel Gear Drive

Cross Section Bevel Gear Assembly

Oil Seal Needle Bearing Retaining Ring Thrust Washer Ball Bearing Bearing Clamp Plate Key

INPUT SHAFT

Oil Seal Needle Bearing

Retaining Ring

Key

Oil Seal Ball Bearing Repair Kit Oil Seal Spacer Oil Seal Shims
(as needed)

Spacer OUTPUT SHAFT

Figure 12. Cross Section of Bevel Gear Assembly

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