Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
T2
®
Integrated Hydrostatic Transaxle
Service and Repair Manual
BLN-52749
December 2008
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Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Description and Operation . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .3
External Features . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . .6
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . .6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tool Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Servicing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . .9
External Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .9
Service and Maintenance Procedures . . . . . . . . . . . .9
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fluid Volume and Level . . . . . . . . . . . . . . . . . . . . . . . .9
Fluid Change Procedure . . . . . . . . . . . . . . . . . . . . . .10
Purging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Return To Neutral Setting . . . . . . . . . . . . . . . . . . . . .12
Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .13
Friction Pack Adjustment . . . . . . . . . . . . . . . . . . . . . .13
Tear Down and Reassembly . . . . . . . . . . . . . . . . . . .14
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . .14
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . .14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Transaxle Removal . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fan and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Control Arm Assembly . . . . . . . . . . . . . . . . . . . . . . .19
Return to Neutral Option . . . . . . . . . . . . . . . . . . . . . .20
Return to Neutral/ROS Assembly Option . . . . . . . . .21
Brake Arm & Brake Assembly . . . . . . . . . . . . . . . . . .22
Side Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
TABLE OF CONTENTS
RH Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Bull Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Reduction Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . .26
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Bypass Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Center Section, Motor Shaft & Motor Block . . . . . . .30
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cylinder Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
LH Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Expansion Tank Hose and Fitting . . . . . . . . . . . . . .33
Assembly after Teardown . . . . . . . . . . . . . . . . . . . . .34
Side Housing-Screw Sequence . . . . . . . . . . . . . . . .35
T2
®
Transaxle Exploded View . . . . . . . . . . . . . . . . .36
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . .38-39
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
T2 ® i
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FOREWORD
H e a d q u a r t e r e d i n S u l l i v a n , I l l i n o i s ,
Hydro-Gear ® is a world leader in the design, manufacture, and service of quality hydrostatic transaxles for the lawn and garden industry.
The mission of our company is to be recognized by our customers and the industry as a world-class supplier and the quality leader in everything we do.
This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro-Gear T2
®
Integrated
Hydrostatic Transaxle.
Also included is a glossary of terms that are frequently used throughout the industry and in
Hydro-Gear service publications. Understanding terminology is very important!
It is necessary, and a good shop practice, that your service area be equipped with the proper tools and the mechanics be supplied the latest information available. All repair procedures illustrated in this guide are suggested, but preferred methods of repair.
Internal repair procedures require that the transaxle unit be removed from the vehicle.
This is not a certifi cation, test or study guide for a certifi cation test. If a technician is interested in certifi cation, they should contact an agent representing the EETC (Equipment and Engine
Training Council) at (262) 367-6700 or their
Hydro-Gear Central Service Distributor. Many distributors will be hosting certifi cation testing.
These study guides will cover most of the products and manufacturers in our industry.
For more information about Hydro-Gear or our products, please contact your Central Service
Distributor, or call our Customer Service Department at (217) 728-2581.
T2 ®
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DESCRIPTION AND OPERATION
INTRODUCTION
The purpose of this manual is to provide information useful in servicing the Hydro-Gear
®
T2
®
Integrated Hydrostatic Transaxle. This manual includes the T2’s general description, hydraulic schematic, technical specifi cations, servicing and troubleshooting procedures.
The transaxle normally will not require servicing during the life of the vehicle in which it is installed. Should other servicing be required, the exterior of the transaxle will need to be thoroughly cleaned before beginning most procedures. Do not wash the transaxle while it is hot. Do not use a pressure washer to clean the unit.
GENERAL DESCRIPTION
The T2 is a self contained unit designed for the transfer and control of power. It provides an infi nitely variable speed range between zero and maximum in both forward and reverse modes of operation.
This transaxle uses a variable displacement pump with a maximum displacement of 8cc per revolution, and motor with a fixed displacement of 10.2cc per revolution. The variable displacement pump features a trunnion mounted swashplate with a direct-proportional displacement control. Reversing the direction of the swashplate reverses the fl ow of oil from the pump and thus reverses the direction of the motor output rotation. The pump and motor are of the axial piston design and utilize spherical nosed pistons which are held against a thrust race by internal compression springs.
The T2 has a self contained fl uid supply and an internal fi lter. The fl uid is forced through the fi lter by a positive “head” on the fl uid in the housing/expansion tank with an assist by the negative pressure created in the pump pistons as they operate.
The check valves in the center section are used to control the makeup fl ow of the fl uid to the low pressure side of the loop.
A block lifting bypass is utilized in the T2 to permit moving the vehicle for a short distance at a maximum of 2 m.p.h. (3.2 Km/h) without starting the engine. The T2 utilizes an in-line fl oating disc brake controlled by a “cam” style actuating arm.
2
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
DESCRIPTION AND OPERATION (CONTINUED)
HYDRAULIC SCHEMATIC
motor. Reversing the angle of the swashplate will reverse the direction of oil fl ow.
Figure 1 is a schematic of the hydraulic oil circuit. The oil supply for the hydraulic system of the T2
®
is also utilized for lubricating the components of the fi nal drive assembly.
The input shaft and pump cylinder block are turned in one direction only by the engine/drive belt/pulley combination. Output of the oil fl ow is controlled by the direction and amount that the variable swashplate is angled. As the pump pistons compress they force the oil to fl ow through one of two passageways (forward or reverse) in the center section to the motor cylinder block and motor shaft. Since the motor has a fi xed displacement angle it is forced to turn with the fl ow of oil. As the angle of the pump swashplate is increased the amount of oil being pumped will increase and cause a higher speed output of the
During the operation of the transaxle, fl uid is “lost” from the hydraulic loop through leak paths designed into the product for lubrication purposes (around pistons, under the rotating cylinder blocks, etc.). This “lost” fl uid returns to the transaxle housing, then is pulled back into one of the check valves depending upon the direction of vehicle operation. All of this oil must pass through an internal fi lter.
The motor cylinder block mounts onto a splined motor shaft which drives the gear train.
The bypass feature in the T2 has a mechanical lever which lifts the motor block off the center section running surface. This allows oil fl ow from the cylinder blocks to be discharged.
T2 ®
Figure 1, T2 Hydraulic Schematic
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4
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EXTERNAL FEATURES T2®
Bypass Arm
Control Arm
Input Shaft
Main Housing
LH Axle RH Axle
Side Housing
RH Axle
Oil Fill Plug
— Top View —
Expansion Tank
Input Shaft
Brake Arm
Control Arm
Expansion Tank
LH Axle
Side Housing Main Housing
— Inboard View —
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
EXTERNAL FEATURES T2®
Expansion Tank
Bypass Arm
Control Arm
LH Axle
Fan
Bypass Arm
Brake Arm
— Outboard View—Left —
Pulley
Oil Fill Plug
Expansion Tank
RH Axle
Brake Rotor
T2 ®
— Outboard View—Right —
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
TECHNICAL SPECIFICATIONS
T2® TECHNICAL SPECIFICATIONS
Overall Transaxle Reduction
Input Speeds
Maximum Hi-Idle (No Load)
Minimum
Output Torque
Peak
Continuous
20.6
395 lb-ft (536 N-m)
105 lb-ft (142 N-m)
3000 rpm
1800 rpm
22.7
425 lb-ft (576 N-m)
115 lb-ft (156 N-m)
Weight on Tires (per unit)
Maximum with 16” tires
Maximum with 18” tires
Axle Shaft Diameter
Axle Shaft End Options
Parking Brake Type
Weight of Unit
Maximum Tire Diameter
540 lb (245 kg)
—
—
500 lb (227 kg)
.75 in (19.05 mm)
Keyed or Two Flats
16 in (406 mm)
Disc
28 lb (12.7) kg
18 in (457 mm)
PRODUCT IDENTIFICATION
The model and confi guration of the T2 can be determined from the label shown below.
H Y D R O - G E A R
BOM Model Number
T2-AABC-2X1A-1CXX T2-AABC-2X1A-1CXX
Sales Drawing Number
Year Built
6 352 K1 476
Assembled in USA
6
Date (Julian- Day of year)
Serial Number (unique for that model - for that day)
Type of Product and Build Information
Figure 2, Confi guration Label
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SAFETY
This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting maintenance on your transaxle. When you see this symbol - HEED ITS WARNING.
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equipment. Before servicing or repairing the
T2® transaxle, fully read and understand the safety precautions described in this section.
PERSONAL SAFETY
Certain safety precautions must be observed while servicing or repairing the T2. This section addresses some of these precautions but must not be considered an all-inclusive source on safety information. This section is to be used in conjunction with all other safety material which may apply, such as:
1. Other manuals pertaining to this machine,
2. Local and shop safety rules and codes,
3. Governmental safety laws and regulations.
Be sure that you know and understand the equipment and the hazards associated with it.
Do not place speed above safety.
Notify your supervisor whenever you feel there is any hazard involving the equipment or the performance of your job.
Never allow untrained or unauthorized personnel to service or repair the equipment.
Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the appropriate safety equipment, such as eye and hearing protection, and safety-toe and slip-proof shoes.
Never use compressed air to clean debris from yourself or your clothing.
TOOL SAFETY
Use the proper tools and equipment for the task.
Inspect each tool before use and replace any tool that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure it is well lit, that extra tools are put away, trash and refuse are in the proper containers, and dirt or debris have been removed from the working areas of the machine.
The fl oor should be clean and dry, and all extension cords or similar trip hazards should be removed.
SERVICING SAFETY
Certain procedures may require the vehicle to be disabled in order to prevent possible injury to the servicing technician and/or bystanders.
The loss of hydrostatic drive line power may result in the loss of hydrostatic braking capability.
Some cleaning solvents are fl ammable. Use only approved cleaning materials: Do not use explosive or fl ammable liquids to clean the equipment.
To avoid possible fi re, do not use cleaning solvents in an area where a source of ignition may be present.
Discard used cleaning material in the appropriate containers.
T2 ® 7
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TROUBLESHOOTING
WARNING
Do not attempt any servicing or adjustments with the engine running.
Use extreme caution while inspecting the drive belt assembly and all vehicle linkage!
Follow all safety procedures outlined in the vehicle owner’s manual.
In many cases, problems with the T2
®
are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages. Be sure to perform all operational checks and adjustments outlined in Service and
Maintenance, before assuming the transaxle is malfunctioning. The table below provides a troubleshooting checklist to help determine the cause of operational problems.
8
TROUBLESHOOTING CHECKLIST
Possible Cause Cor rective Action
Unit Operates In One Direction Only
Control linkage bent or out of adjustment Repair or replace linkage, Page 9
Drive belt slipping or pulley damaged Repair or replace drive belt or pulley, Page 9
Vehicle Does Not Drive/Track Straight
Vehicle tires improperly infl ated Refer to vehicle manufacturer suggested pressure
Control linkage bent or out of adjustment Repair or replace linkage, Pages 9 and 12
Bypass assembly sticking
Brake Partially Engage
Repair or replace bypass, Page 29
Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Is Noisy
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Oil level low or contaminated oil
Excessive loading
Loose parts
Bypass assembly sticking
Air trapped in hydraulic system
Brake Partially Engage
Repair or replace loose parts
Repair or replace linkage, Page 9
Purge hydraulic system, Page 11
Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Has No/Low Power
Adjust to correct setting Engine speed low
Control linkage bent or out of adjustment
Drive belt slipping or pulley damaged
Oil level low or contaminated oil
Excessive loading
Bypass assembly sticking
Air trapped in hydraulic system
Brake Partially Engage
Repair or replace linkage, Page 9
Repair or replace drive belt or pulley, Page 9
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Repair or replace linkage, Page 9
Purge hydraulic system, Page 11
Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Is Operating Hot
Clean off debris, Page 9
Repair or replace cooling fan, Pages 17
Debris buildup around transaxle
Cooling fan damaged
Oil level low or contaminated oil
Excessive loading
Air trapped in hydraulic system
Brake Partially Engage
Damaged seals, housing, or gaskets
Air trapped in hydraulic system
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Purge hydraulic system, Page 11
Disengage Brake, Replace Broken or Missing Brake Return Spring
Transaxle Leaks Oil
Replace damaged components
Purge hydraulic system, Page 11
T2
®
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SERVICE AND MAINTENANCE
NOTE: Any servicing dealer attempting a warranty repair must have prior approval before conducting maintenance of a Hydro-Gear® product unless the servicing dealer is a current Authorized Hydro-Gear Service
Center.
EXTERNAL MAINTENANCE
Regular external maintenance of the T2
®
should include the following:
1. Check the vehicle operator’s manual for the recommended load ratings. Insure the current application does not exceed load rating.
2. Check oil level in accordance with Figure 3
Page 10.
3. Inspect the vehicle drive belt, idler pulley(s), and idler spring(s). Insure that no belt slippage can occur. Slippage can cause low input speed to the transmission.
4. Inspect the transmission cooling fan for broken or distorted blades and remove any obstructions (grass clippings, leaves, dirt, etc.).
5. Inspect the axle parking brake and vehicle linkage to insure proper actuation and adjustment of the parking brake.
6. Inspect the vehicle control linkage to the directional control arm on transaxle. Also, insure the control arm is securely fastened to the trunnion arm of the transaxle.
7. Inspect the bypass mechanism on the transaxle and vehicle linkage to insure it actuates and releases fully.
SERVICE AND MAINTENANCE
PROCEDURES
All the service and maintenance procedures presented on the following pages can be performed while the T2 is mounted on the vehicle. Any repair procedures as mentioned in the repair section of this manual must be performed after the unit has been removed from the vehicle.
FLUIDS
The fl uids used in Hydro-Gear products have been carefully selected, and only equivalent, or better products should be substituted.
Typically, an engine oil with a minimum rating of 9.0 cSt (55 SUS) at 230°F (110° C) and an API classifi cation of SL is recommended. A 20W-50 engine oil has been selected for use by the factory and is recommended for normal operating temperatures.
FLUID VOLUME AND LEVEL
Fluid volume information is provided in the
Table below.
Certain situations may require additional fl uid to be added or even replaced. Refer to Page
10, Figure 3 and pages 4 and 5 for the proper fi ll port location.
Fill the T2 to the bottom of the oil fill port threads.
Recheck the fl uid level once the unit has been operated for approximately 1 minute.
Purging may be required. Refer to the purging procedures on page 11.
Fluid Description
Type: 20W50 motor oil
Fluid Volume (per transaxle)
10 Bolt Housing: 69.3 - 65.9 fl .oz. (2050 - 1950 ml)
14 Bolt Housing: 72.8 - 69.4 fl . oz. (2155 - 2055 ml)
T2 ® 9
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FLUID CHANGE PROCEDURE
This transaxle is factory fi lled, sealed and does not require oil maintenance. However, in the event of oil contamination or degradation, oil addition or change may alleviate certain performance problems.
1. Remove the transaxle from the vehicle.
2. Clean the expansion tank and oil fi ll port areas of any debris.
3. Remove the oil fi ll port fi tting.
4. Position the transaxle so the oil will drain completely out of the housing.
5. After all the oil is drained from the transaxle, remove the expansion tank by removing the self tapping bolt (10-32 x ½) and ratchet fastner that holds the tank to the housing.
6. Remove the tank and drain the oil from the tank. DO NOT remove the vent cap from the tank. DO NOT remove the tank hose or o-ring unless a replacement is needed.
7. Install the tank by fi rst inserting the hose into the opening in the expansion tank.
Push the tank opening over the o-ring to ensure a proper seal.
8. Install the tank and self tapping bolt making sure not to cross thread the bolt. Torque the bolt to the lower value of the torque specifi cation listed in the Table on page 15.
9. Fill the transaxle at the oil fi ll port according to Figure 3.
10. Install the oil fi ll port fi tting.
EXPANSION TANK FUNCTION
The expansion tank allows the T2™ to operate free of air entrainment and provides maximum lubrication to the mechanical and hydraulic components in the transaxle.
As the T2 transaxle is operated, oil in the transaxle housing heats up which causes the oil to expand. The oil fl ows through an internal hose to the bottom of the vented expansion tank. As the oil cools, the oil in the transaxle housing contracts, causing the oil level to go down in the housing. This creates a negative pressure in the housing causing the oil to be drawn back into the case. This keeps the transaxle housing full of oil at specifi ed operating temperatures.
Top of Fill Port
1.25
.50
Oil Level
Expansion Tank
10
Oil Volume (10 bolt housing)
2050 ml (69.3 fl. oz.)
1950 ml (65.9 fl. oz.)
Figure 3, Expansion Tank
Oil Volume (14 bolt housing)
2155 ml (72.8 fl. oz.)
2055 ml (69.4 fl. oz.)
T2
®
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PURGING PROCEDURES
Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system.
These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.
Air creates ineffi ciency because its compression and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems.
The resulting symptoms in hydrostatic systems may be:
1. Noisy operation.
2. Lack of power or drive after short term operation.
3. High operation temperature and excessive expansion of oil.
Before starting, make sure the transaxle/transmission is at the proper oil level. If it is not, fi ll to the specifi cations outlined on page 9.
The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.
1. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions
(5 to 6 times), as air is purged from the unit, the oil level will drop.
2. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping engine.
3. It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system. When the transaxle moves forward and reverse at normal speed purging is complete.
T2 ®
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RETURN TO NEUTRAL SETTING
WARNING
POTENTIAL FOR SERIOUS INJURY
Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured.
WARNING
Do not attempt any adjustments with the engine running. Use extreme caution while inspecting all vehicle linkage!
Follow all safety procedures outlined in the vehicle owner’s manual.
The return to neutral mechanism on the transmission is designed to set the directional control into a neutral position when the operator removes their foot from the foot control. Follow the procedures below to properly adjust the return to neutral mechanism on the transaxle:
1. Confi rm the transaxle is in the operating mode
(bypass disengaged). Raise the vehicle’s drive tires off the ground to allow free rotation.
NOTE: It may be necessary to remove the
drive tire from the axle hub to access
the linkage control and the transaxle
return arm.
2. Remove the Original Equipment Manufacturer’s (OEM’s) control linkage at the control arm. Refer to Figure 4.
3. Start the engine and increase the throttle to full engine speed.
4. Check for axle rotation. If the axles do not rotate, go to Step 5. If the axles rotate, go to Step 6.
5. Stop the vehicle’s engine. Reattach and adjust the OEM linkage according to the OEM manual. Recheck according to
Step 3 and 4. Stop the vehicle engine.
Refer to Figure 4.
6. Note the axle directional movement. Stop the vehicle engine. Loosen the lock down screw (168) until the control arm (160) can be rotated. Rotate the control arm in the same direction of the wheel rotation in small increments. Tighten the lock down screw.
Recheck according to steps 3 and 4. Refer to Figure 4.
Spring (167)
Screw (41)
RTN Control Arm (160)
Lock Down Screw (168)
Bushing (165)
12
Scissor Arm (162)
RTN Neutral Arm (161)
Figure 4, Return to Neutral
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
BRAKE MAINTENANCE
BRAKE SETTING FRICTION PACK ADJUSTMENT
1. Remove the brake arm bias spring(134), and then the cotter pin (133) securing the brake castle nut (132).
2. Insert a 0.020” feeler gage between the brake rotor (121) and top brake puck, and then set the brake by fi nger tightening or loosening the castle nut.
3. Install a new cotter pin to secure the castle nut, and then install the brake arm bias spring.
(130)
The friction pack dampens or holds the operator control lever in its desired position.
Adjustment for the amount of drag or holding force can be made by turning the friction pack nut in or out.
Adjustments should be made in no more than
1/4 turn increments.
Over-tightening will result in diffi culty or inability of the operator to move the control lever.
NOTE: The factory setting for the friction pack is tightening of the friction pack nut to 100 in-lbs (11 Nm) torque. The friction pack nut is then backed off per the vehicle manufacturer’s specifi cations.
(134)
(132)
Friction Pack Nut
(121) (133) (124)
Figure 5, Brake Setting
Figure 6, Friction Pack Adjustment
T2 ®
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TEAR DOWN AND REASSEMBLY
HOW TO USE THIS MANUAL
Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved. The item reference num-
bers in each illustration are for assembly
instructions only. See page 37 for part names
and descriptions. A complete exploded view and item list of the transaxle is provided on pages 36 and 37.
Many of the parts and subassemblies of this transaxle can be removed and serviced independently of other components. Where some components and assemblies must be removed before a given assembly can be serviced, that information is given at the beginning of the disassembly instructions.
Hydro-Gear
®
replacement parts found listed in
BLN-51427 (CD).
IMPORTANT: When internal repair is performed on the T2
®
, the fi lter assembly must be replaced.
TRANSAXLE REMOVAL
It is necessary to remove the T2 from the vehicle before performing the repair procedures presented in this section.
GENERAL INSTRUCTIONS
Cleanliness is a primary means of assuring satisfactory life on repaired units. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material. The external surfaces should be cleaned before beginning any repairs.
Upon removal, it is recommended that all seals,
O-rings, and gaskets be replaced. During installation lightly lubricate all seals, O-rings, gaskets with a clean petroleum jelly prior to assembly. Also protect the inner diameter of seals by covering the shaft with a cellophane
(plastic wrap, etc.) material. Be sure all remnants of this covering are removed after servicing.
Parts requiring replacement must be replaced from the appropriate kits identifi ed in the Items
Listing, found on page 37. Use only original
LIMITED DISASSEMBLY
The following procedures are presented in the order in which they must be performed to completely disassemble the unit. Do not disassemble the unit any farther than is necessary to accomplish the required repairs.
Each disassembly procedure is followed by a corresponding assembly procedure.
Reassembly is accomplished by performing the “Assembly” portions of the procedures. If the unit has been completely disassembled, a summary of the assembly procedures, in the order in which they should occur, is given on page 34.
14 T2
®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
TOOLS
Miscellaneous
Flat Blade Screw Driver (2)
Torque Wrench
Air Impact Wrench
Rubber or Neoprene Mallet
Breaker Bar
Side Cutters/Snips
Needle Nose Pliers
Large External Snap Ring Pliers
Small Internal Snap Ring Pliers
REQUIRED TOOLS
1/2”-3/8” Adapter
1/2” Deep
7/16” Deep
3/4” Deep
7/8” Deep
9/16” Deep
T-40 Torx Head
10 mm
Sockets
TORQUES
REQUIRED TORQUE VALUES
Item Description
8 HFHCS 1/4-20 x 1.25
13 Plug 9/16-18 (Metal)
22 Bolt, Hex Flange, 3/8-16, CS
24 Check plug
25 Check plug
41 TWHCS 5/16-18 x 1
43 Screw, set 5/16-24 x 2.50
49 Nut, hex 5/16-24 nylon insert
127 HFHCS 1/4-20 x 2.0 w/ patch
128 HHCS 1/4-20 x 1 (patch)
140 5/16 SAE, 5/32 tube
144 Bolt, self-tapping 10-32 x 0.5
152 Nut, Hex Lock 1/2-20
153 HFHCS 1/4-20 x 0.75
162 Screw, Hex Flange Head
Torque
105-155 in-lbs [11.8-17.5 Nm]
180-240 in-lbs [20.3-27.1 Nm]
525-700 in-lbs [59.3-79.1 Nm]
280-400 in-lbs [31.6-45.2 Nm]
280-400 in-lbs [31.6-45.2 Nm]
230-310 in-lbs [25.9-35.0 Nm]
135-155 in-lbs [15.2-17.5 Nm]
85-120 in-lbs [9.6-13.5 Nm]
80-120 in-lbs [9.0-13.5 Nm]
80-120 in-lbs [9.0-13.5 Nm]
96-120 in-lbs [10.8-13.5 Nm]
25-40 in-lbs [2.8-4.5 Nm]
360-520 in-lbs [40.7-58.8 Nm]
50-80 in-lbs [5.7-9.0 Nm]
85-120 in-lbs[9.6-13.5 Nm]
Operation
Housing screw
Fill plug
Center section bolt
Check plugs
Check plugs
Trunnion arm screw
Control arm stud
Friction Pack Nut
Brake yoke screw
Brake yoke screw
Expansion tank fi tting
Expansion tank screw
Fan Nut
Fan Screws
Neutral Assy Arm Screw
As a general rule, use the low end of the torque spec on fasteners when reassembling the unit.
T2 ®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
TRANSAXLE REMOVAL
NOTE: It is necessary to remove the T2
®
from the vehicle before performing the repair procedures presented in this section.
Before starting any disassembly, make certain that your work area is neat and clean. Clean the external parts of the transaxle.
The following procedures are presented in the order recommended for a complete tear down of the transaxle.
Do not disassemble the unit any farther than necessary to accomplish the required repairs.
Reassembly is accomplished by performing the “Assembly” portions of the procedures. If the unit has been completely disassembled, a summary of the assembly procedures, in the order in which they should occur, is given on page 34.
16
Figure 7, T2 Transaxle
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
FAN AND PULLEY
Refer to Figure 8
PULLEY AND FAN CONFIGURATION
1. Remove the locknut (152), and detach the fan and pulley assembly from the input shaft.
2. Separate the assembly by removing the screws (153), fan (150) and the pulley
(151).
I
nspection
1. Check all components for wear or damage.
Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
NOTE: As a general rule, use the low end of the torque specifi cation on fasteners when reassembling the unit.
Refer to Figure 9
FAN AND PULLEY CONFIGURATION
1. Remove the locknut (152) and washer
(153).
2. Remove the fan (150) and the pulley
(151).
I
nspection
1. Check all components for wear or damage.
Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
152
152
153
151
150
150
151
153
T2 ®
Figure 8, Fan on bottom confi guration Figure 9, Fan on top confi guration
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17
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
EXPANSION TANK
Refer to Figure 10
Disassembly
1. Remove all items previously discussed in their recommended order.
2. Remove the ratchet fastener (147) and discard.
3. Detach the tube (145) from the tank fi tting
(146). The fi tting (146) does not need to be removed – unless, replacing.
4. Remove the screw (144) from the expansion tank.
5. Remove the tank (143). Do not remove the hose (141) at this time.
Inspection
1. Inspect all parts for wear or damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
NOTE: As a general rule, use the low end of the torque specifi cation on fasteners when reassembling the unit.
147
144
145
143
146
141
18
Figure 10, Expansion Tank
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
CONTROL ARM ASSEMBLY
Refer to Figure 11
Disassembly
1. Remove all items previously discussed in their recommended order.
2. If opening the housing or replacing seals, remove the oil port plug (13), then; drain oil from transaxle.
3. Remove the lock nut (49), the washer (46), the helical comp spring (48), the spacer
(47), the (second) washer (46), and the plastic washer (45).
4. Remove the Torx head screw (41) and discard.
5. Remove the control arm (42), the (second) washer (45), the belleville washer (44), and and the set screw (43).
Inspection
1. Inspect all parts for wear or damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
3. Install new Torx head screw (41) and lip seal
(110) from seal kit, if removed.
NOTE: As a general rule, use the low end of the torque specifi cation on fasteners when reassembling the unit.
49
46
48
47
46
41
45
42
45
44
43
110
NOTE: Only remove the seal (110) if doing a complete disassembly or if the seal is worn or damaged.
T2 ®
Figure 11, Control Arm
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13
19
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
RETURN TO NEUTRAL ASSEMBLY OPTION
Refer to Figure 12
Disassembly
1. Remove all items previously discussed in their recommended order.
2. Remove the spring (167).
3. Remove the Torx head screw (41) and discard.
4. Remove the scissor arm (164), and the RTN control arm (161).
5. Remove the Hex fl ange head screw (162), the bushing (166) and the RTN neutral arm
(165).
NOTE: Only remove the seal (110) if damaged or worn, or if doing a complete disassembly. Refer to “Seal Kit” in the Items
List on page 37.
Inspection
1. Inspect all parts for wear or damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
3. Install new Torx head screw (41) and lip seal
(110) from seal kit.
NOTE: As a general rule, use the low end of the torque specifi cation on fasteners when reassembling the unit.
41
162
166
167
164
161
165
110
20
Figure 12, Return to Neutral Assembly
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
RETURN TO NEUTRAL/ROS ASSEMBLY OPTION
Refer to Figure 13
Disassembly
1. Remove all items previously discussed in their recommended order.
2. Remove the spring (167).
3. Remove the Torx head screw (41), discard, and the washer (163).
4. Remove the scissor arm (164), and the RTN control arm (160).
5. Remove the Hex fl ange head screw (162), the bushing (166) and the RTN neutral arm
(165).
Inspection
1. Inspect all parts for wear or damage. Replace if necessary.
Assembly
1. Install the neutral arm (165).
2. Install the bushing (166) and the hex head screw (162).
3. Install the control arm (160).
4. Install the RTN scissor arm (164), washer
(163) and Torx head screw (41). Refer to torque chart on page 15.
5. Install the switch retainer over the neutral arm tab. Place the rivet through the switch retainer and neutral arm.
6. Install the RTN spring (167).
7. Press down on the switch retainer tab to bias it. Ensure that the rivet is seated. Then set the rivet using a rivet gun.
8. Refer to page 12 for adjusting the RTN assembly.
NOTE: After installing the transaxle on the vehicle be sure the operator presence system and the reverse operation system (ROS) are working properly.
Refer to the operations and maintenance sections in the vehicle owner’s manual.
163
41
164
Actuator clip
T2 ®
160
162
166
165
RCS switch
167
Switch retainer
Figure 13, Return to Neutral/ROS Assembly
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21
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
BRAKE ARM & BRAKE ASSEMBLY
Refer to Figure 14
Disassembly
1. Remove all items previously discussed in their recommended order.
2. Remove the cotter pin (133) and discard.
Mark the orientation of the bias spring (134), and long screw (127). Remove the brake arm spring (134), the castle nut (132), and the washer (131).
3. Remove the brake arm (130), and the brake compression spring (129).
4. Remove the bolt (128), the bolt (127), and the spacer (126).
5. Remove the brake yoke (124), the puck plate (122), and the brake puck (120).
6. Remove the two brake pins (125) from the brake yoke (124).
7. Remove the brake rotor (121), the inner puck (120) and the seal (7) and discard.
NOTE: Only remove the seal (7) if damaged or worn, or if doing a complete disassembly. Refer to “Seal Kit” in the Items
List on page 37.
Inspection
1. Inspect all parts for wear or damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. When tightening the fasteners, refer to the table on page 15 for the required torque values.
3. Install new cotter pin (133) and lip seal (7) from seal kit.
NOTE: As a general rule, use the low end of the torque specifi cation on fasteners when reassembling the unit.
7
22
120
121
120
122
124
125
126
127
125
129
128
134
130
131
133
132
Figure 14, Brake Assembly
T2
®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SIDE HOUSING
Refer to Figure 15
Disassembly
1. Remove all external items previously discussed in their recommended order.
2. Remove the screws (8), separate side housing (2) from main housing (1).
Inspection
1. Inspect the bearing and bushing areas in the side cover for wear or damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Apply a bead of sealant around the perimeter of the main housing face. See “Sealant
Application Diagram” on page 34.
3. Align the side housing (2) with the main housing (1). Use care not to smear the sealant bead.
4. Install the housing screws (8). Refer to the screw tightening pattern on page 35.
5. When tightening the fasteners, refer to the table on page 15 for the required torque values.
Side Housing (2)
8
Main Housing (1)
T2 ®
Figure 15, Side Housing Removal
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23
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
RH AXLE SHAFT
Refer to Figure 16
Disassembly
1. Remove all items previously discussed, in their recommended order.
2. Remove the retaining ring (109) and discard.
3. Remove the lip seal (110) and discard.
4. Remove the outboard bushing (106).
5. Remove the axle shaft (103) in the direction of arrow.
6. Remove the inner bushing (105).
Inspection
1. Inspect the axle shaft for wear or damage.
Replace if necessary.
100
Assembly
1. Assemble items in reverse order of disassembly.
NOTE: To protect the lip seal from possible damage when installing into the bore and over the axle shaft, apply a protective covering over the splines, sharp corners and/or keyway of the axle shaft
(e.g., cellophane, tape, etc.). Remove protective covering after installation.
101
103
105
2
24
Figure 16, Axle Assembly
www.mymowerparts.com
106
110
109
T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
BULL GEAR SET
Refer to Figure 17
Disassembly
1. Remove all external items previously discussed in their recommended order.
2. Remove the bull gear set — two miter gears
(102) with two differential pins (108), and bull gear (107).
Inspection
1. Inspect all items of the bull gear set for wear or damage.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Install the bull gear (107).
3. Install the miter gears (102) with the differential pins (108).
T2 ®
1
Figure 17, Bull Gear Set
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102
108
107
108
102
25
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
REDUCTION GEAR SET
Refer to Figure 18
Disassembly
Reduction Gear Set:
1. Remove all external items previously discussed in their recommended order.
2. Remove the washer (93), jack shaft gear
(91) and reduction gear (90).
3. Remove the jack shaft (92) and second washer (93).
Inspection
1. Inspect all items of the reduction gear set for wear or damage.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Install the washer (93) and jack shaft (92).
3. Install the jack shaft gear (91) into the reduction gear (90). Insert onto the jack shaft
(92).
4. Place the washer (93) onto the jack shaft
(92).
1
93
92
90
91
93
Figure 18, Reduction Gear Set
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®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
INPUT SHAFT
Refer to Figure 19
Disassembly
1. Remove all external items previously discussed in their recommended order.
2. Remove the retaining ring (66) and discard.
3. Remove the lip seal (65) and discard.
4. Remove the washer (64).
5. Remove the pump shaft (61) with pressed on bearing (62), and the helical spring
(67).
NOTE: Remove the bearing from pump shaft only if worn or damaged.
6. Remove the wire ring retainer (63) and discard. Remove the bearing (62) from the pump shaft (61).
Inspection
1. Inspect the bearing and input shaft for wear or damage. Inspect the splines on the shaft for possible damage. Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Install the bearing (62), a new retaining wire
(63), and spring (67) onto the input shaft.
NOTE: Apply a light coating of grease to new seal (65) before installing. Refer to
“Seal Kit” in the Items List on page
37.
3. Install the input shaft assembly into the main housing.
4. Install the washer (64), seal (65) and retaining ring (66) into the main housing.
66
65
64
63
62
61
67
T2 ®
Figure 19, Input Shaft
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27
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SWASHPLATE
Refer to Figures 20-21
Disassembly
1. Requires removal of all items beginning on page 17.
2. Remove the swashplate (40) and pump cylinder block assembly (70) as a single item.
NOTE: Removal will be aided by applying a small amount of pressure on the trunnion mounted swashplate towards the center section. While CAREFULLY removing the swashplate and block assembly, keep the block face fl ush with the center section to minimize damage to the running surface.
3. Separate the pump cylinder block assembly
(70) and the thrust bearing (74) from the swashplate (40) and set aside.
Inspection
1. Inspect the swashplate (40) and thrust bearing assembly (74) for wear or damage.
Replace if necessary.
2. Inspect pump block per detail on page 31.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Apply a light coating of oil to running surfaces on center section, swashplate bearing races, thrust bearing assembly and pump block assembly.
3. Place the thrust bearing assembly (74) into swashplate (40).
4. With the pistons facing the thrust bearing, place the pump block assembly (70) into the swashplate.
5. While pressing the pump block assembly
(thrust bearing – pump cylinder block) and swashplate together, align to center section in main housing.
40
74
70
40
Figure 21, Hydraulic Pump Components
28
70
Figure 20, Swash Plate
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
BYPASS ARM
Refer to Figure 22
Disassembly
1. Remove all external items previously discussed in their recommended order.
2. Remove the retaining ring (35) and discard.
Remove the bypass arm (34).
3. Remove the retaining ring (33) and discard.
4. Remove the bypass rod (32) and the clip retaining ring (31) as a single item.
NOTE: It is not necessary to remove the clip retaining ring (31) from the bypass rod
(32) unless it is damaged or worn.
5. Remove the lip seal (30) and discard.
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Install a new lip seal (30).
3. Install the bypass rod (32) with new clip retaining ring (31), if removed.
4. Install the new retaining ring (33).
5. Install the bypass arm (34).
6. Install the retaining ring (35).
Inspection
1. Inspect the bypass rod (32) for wear or damage. Replace if necessary.
NOTE: Take care to insure that the bypass rod is free of burrs that may cut the rubber lip seal.
2. Inspect the housing bore.
35
34
33
31
32
30
T2 ®
Figure 22, Bypass Arm and Rod
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29
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
CENTER SECTION, MOTOR SHAFT & MOTOR BLOCK
Refer to Figure 23
Disassembly
1. Requires removal of all items beginning on page 17.
2. Remove the center section mounting screws
(22).
Assembly
1. Reassemble all parts in the reverse order of disassembly.
2. Apply a light coating of oil to all running surfaces.
3. Remove the center section, the motor shaft
(82) and the bypass plate (23).
4. Remove the motor cylinder block assembly
(75).
5. Remove the motor thrust bearing (79).
3. Place the thrust bearing assembly (79) into the main housing. Position so the thick race will contact the motor block pistons.
4. Insert the motor shaft assembly (82) into the center section (20).
Inspection
1. Inspect the races of the thrust bearing (79) for wear or damage.
2. Inspect the motor shaft for wear or damage.
Replace if necessary.
3. Inspect for scratches on the machined surfaces of the center section.
4. Inspect motor cylinder block assembly (75) per detail on page 30.
5. Insert the bypass plate (23) into the center section.
6. Place the motor cylinder block assembly
(75) onto the motor shaft (82).
7. Insert the center section (20), the motor shaft (82), the bypass plate (23) and the motor cylinder block (75) into the main housing as one assembly.
8. Install the center section screws (22). Refer to torque chart on page 15.
5. Inspect the bearing surfaces in the main housing.
23
20
22
22
30
79
75
83
82
81
80
Figure 23, Center Section, Motor Shaft & Motor Block
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93
T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
FILTER ASSEMBLY
Refer to Figure 24
Disassembly
1. Remove the magnet (28) and the fi lter (27).
The fi lter can be removed without damaging the fi lter base.
2. Remove the defl ector (29).
3. Inspect the check plugs (24, 25). Remove if necessary.
4. Inspect the fi lter base (26). Remove/replace if necessary.
Inspection
1. Inspect all parts for wear or damage. Replace as necessary.
Assembly
1. Install the fi lter base, if removed.
2. Install the check plugs, if removed. Refer to torque chart on page 15.
3. Install the defl ector (29).
4. Install a new fi lter (27) and the magnet
(28).
20
CYLINDER BLOCKS
Refer to Figure 25
Inspect each component of the cylinder block assemblies for wear or damage. Inspect the cylinder blocks’ running surface for scratches.
Replace if necessary.
NOTE: During separation of the cylinder blocks, take care not to damage the surfaces of the pistons and block.
Apply a thin coating of oil to all components of the cylinder block assemblies before reassembly.
After reassembling the cylinder block components, set aside until ready for installation of the center section and swashplate. Refer to pages 28 and 30.
Pistons
Thrust Washers
Springs
T2 ®
Cylinder Block
22
25
26
24
29
Figure 25, Pump/Motor Cylinder Block Assembly
27
28
Figure 24, Filter Assembly
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31
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
LH AXLE SHAFT
Refer to Figure 26
Disassembly
1. Remove all items previously discussed, in their recommended order.
2. Remove the retaining ring (109) and discard.
3. Remove the lip seal (110) and discard.
4. Remove the outboard bushing (106).
5. Remove the axle shaft (104) in the direction of arrow.
6. Remove the inner bushing (105).
Inspection
1. Inspect the axle shaft for wear or damage.
Replace if necessary.
109
110
106
Assembly
1. Assemble items in reverse order of disassembly.
NOTE: To protect the lip seal from possible damage when installing into the bore and over the axle shaft, apply a protective covering over the splines, sharp corners and/or keyway of the axle shaft
(e.g., cellophane, tape, etc.). Remove protective covering after installation.
1
105
104
101
100
32
Figure 26, Axle Assembly
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
EXPANSION TANK HOSE AND FITTING
Refer to Figure 27
Disassembly
1. Remove the expansion tank hose (141).
2. Remove the O-ring (142) from the expansion tank fi tting (140) and discard.
3. Remove the expansion tank fi tting (140).
Inspection
1. Inspect the fi tting for damage and replace if necessary.
Assembly
1. Install the fi tting into the main housing. Refer to torque chart on page 15.
2. Install a new O-ring (142) onto the fi tting.
3. Place the expansion tank hose (141) onto the fi tting (140).
141
142
140
Figure 27, Expansion Tank Hose and Fitting
T2 ®
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33
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
ASSEMBLY AFTER A COMPLETE TEAR DOWN
If the unit has been torn down completely, the following summary identifi es the assembly procedures necessary to completely assemble the unit. Each assembly procedure is located by a page reference.
The part reference numbers provided in each assembly procedure are keyed to the individual procedure illustrations, and are also keyed to the complete unit exploded view on page 36.
1. Install the expansion tank hose and fi tting.
See page 33.
2. Install the LH axle assembly. See page
32.
3. Install the fi lter assembly, cylinder block and motor shaft. See pages 30-31.
4. Install the bypass arm. See page 29.
5. Install the pump block and swash plate. See page 28.
6. Install the input shaft. See page 27.
7. Install the reduction gear set. See page
26.
8. Install the bull gear set. See page 25.
9. Install the RH axle assembly. See page
24.
10. Apply sealant to the main housing prior to assembly with the side housing. See page
34.
NOTE: Prior to applying the new sealant, the old sealant must be removed from all surfaces.
A small consistent bead (approx.
1/16 – 1/8 inch) of the sealant around the housing face will be suffi cient. Use sparingly.
The illustration below indicates the correct sealant path.
11. Install the brake assembly. See page 22.
12. Install the control arm (RTN) assembly. See pages 19-21.
13. Install the expansion tank. See page 18.
14. Fill transaxle with clean oil.
15. Install the fan and pulley assembly. See page 17.
16. Install the transaxle into the vehicle.
17. Perform the purge procedures listed on page 11.
Sealant Path for Main Housing
34
Figure 28, Sealant Application Diagram
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SIDE HOUSING – SCREW TIGHTENING SEQUENCE
Starting with the number “1” screw location, tighten sequentially through to “10.”
Torque each screw to 105 – 155 lb-in (11.8 – 17.5 Nm).
NOTE: As a general rule, use the low end of the torque specifi cation.
10 Bolt Housing
T2 ®
Figure 29, Screw tightening sequence
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14 Bolt Housing
35
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
T2
®
TRANSAXLE EXPLODED VIEW
36
www.mymowerparts.com
T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
T2
®
TRANSAXLE PARTS LIST
35
40
41
32
33
34
29
30
31
26
27
28
23
24
25
13
20
22
8
10
11
1
2
7
Housing, Main
Housing, Side
Seal, Lip (included in Center Section Kit 202)
HFHCS 1/4-20 x 1.25
Sealant, Loctite 5900
Oil, 20W50
Plug
Center Section
Bolt, Hex Flange
Plate, Bypass
Check Plug Assembly w/Washer
Check Plug/w Assembly w/Washer, .027, Spring
Bottom, Filter
Cover, Filter
Ring, Magnet
Defl ector
Seal, Lip (included in Center Section Kit 202)
Ring, Retaining (included in Center Section Kit 202)
Rod, Actuator
Ring, Retaining (included in Center Section Kit 202)
Arm, Bypass
Ring, Retaining (included in Center Section Kit 202)
Trunnion, Swashplate
TWHCS 5/16-18 x 1.00
81
82
83
75
79
80
67
70
74
64
65
66
61
62
63
47
48
49
42
43
44
45
46
Arm, Control
Screw, Set 5/16-24 x 2.50
Washer , Belleville
Washer, Plastic .32 x .80 x .21
Washer .34 x .88 x .06
Spacer .32 x .59 x .50
Spring, Helical Comp
Nut, Hex 5/16-24 nylon insert
Input Shaft
Bearing, Ball 15 x 35 x 11
Ring, Retaining (included in Center Section Kit 202)
Washer 1.23 x 1.56 x .04
Seal, Lip (included in Center Section Kit 202)
Ring, Retaining (included in Center Section Kit 202)
Spring, Helical
Block, Cylinder 8cc
Bearing, Thrust 27 x 47 x 14
Block, Cylinder 10cc
Bearing, Thrust Ball 30 x 52 x 13
Ring, Retaining .50 External Motor Shaft (part of 202)
Gear, 13T Pinion
Shaft, Motor
Washer .60 x 1.00 x .03
90
91
92
Gear
Gear, Jack Shaft 11T
Jack Shaft (Pin)
93 Washer .50 x 1.00 x .03
100 Ring, Retainer (included in Center Section Kit 202)
101 Gear, Bevel 12T Spline ID
102 Gear, Bevel 12T .50 ID
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103 Axle .75 dia. RH
104 Axle .75 dia. LH
105 Bushing, Inboard
106 Bushing, Outboard
107 Gear 53T Bull
108 Pin, Differential
109 Ring, Retaining Internal Axle (part of 202)
110 Seal, Lip .75 x 1.125 x .25 TC (part of 202)
120 Puck, Brake
121 Rotor, Brake
122 Plate, Puck
124 Yoke, Brake
125 Pin, Brake
126 Spacer
127 Screw 1/4-20 x 2.0 w/Patch
128 Screw 1/4-20 x 1.0 w/Patch
129 Spring
130 Arm, Brake
131 Washer
132 Nut, Castle 5/16-24 PL
133 Pin, Cotter 3/32 x .75
134 Spring, Brake arm
140 5/16 SAE, 5/32 Tube
141 Hose
142 O-Ring .103 x .299 ID (part of 202)
143 Tank, Expansion
144 Bolt, Self Tapping 10-32 x 1/2, patch
145 Tube
146 Cap, Barbed Vent
150 Fan
151 Pulley
152 Nut
153 Washer
153 Screw 1/4-20 x 0.75
160 Arm, Control RTN
161 Arm, Control RTN
162 Bolt, Hex Flange Head
163 Bushing
164 Assembly, RTN Bi-Directional
165 Arm, Neutral Assembly
166 Bushing
167 Spring
200 Kit, Filter
201 Center Section w/Filter
202 Center Section Kit
205 Seal Kit
206 Kit, T2
®
ROS
207 Kit, T2
®
ROS
37
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
GLOSSARY OF TERMS
Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged parallel with the spindle (input or output shaft).
Bypass Valve: A valve whose primary function is to open a path for the fl uid to bypass the motor or pump. Also referred to occasionally as the freewheel valve or dump valve.
Case Drain Line (Return Line): A line returning fl uid from the component housing to the reservoir.
Cavitation: A concentrated gaseous condition within the fl uid causing the rapid implosion of a gaseous bubble.
Center Section: A device which acts as the valve body and manifold of the transmission.
Charge Pump: A device which supplies replenishing fl uid to the fl uid power system (closed loop).
Charge Pressure: The pressure at which replenishing fl uid is forced into a fl uid power system.
Charge Relief Valve: A pressure control valve whose primary function is to limit pressure in the charge circuit.
Check Valve: A valve whose primary function is to restrict fl ow in one direction.
Closed Loop: A sealed and uninterrupted circulating path for fl uid fl ow from the pump to the motor and back.
Decay Rate: The ratio of pressure decay over time.
End Cap: See “Center Section.”
Entrained Air: A mechanically generated mixture of air bubbles having a tendency to separate from the liquid phase.
Gerotor: A formed rotor set operating about an eccentric that provides a fi xed displacement for pumps or motors.
Hydraulic Motor: A device which converts hydraulic fl uid power into mechanical force and motion by transfer of fl ow under pressure.
Hydraulic Pump: A device which converts mechanical force and motion into hydraulic fl uid power by producing fl ow.
Hydrostatic Pump: See “Hydraulic Pump.”
Hydrostatic Transaxle: A multi component assembly including a gear case and a hydrostatitransmission.
Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to form a device for the control and transfer of power.
Inlet Line: A supply line to the pump.
38 T2
®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Integrated Zero-Turn Transaxle: The combination of a hydrostatic transmission and gear case in one housing to form a complete transaxle.
Manifold: A conductor which provides multiple connection ports.
Neutral: Typically described as a condition in which fl uid fl ow and system pressure is below that which is required to turn the output shaft of the motor.
Pressure Decay: A falling pressure.
Priming: The fi lling of the charge circuit and closed loop of the fl uid power system during start up, frequently achieved by pressurizing the fl uid in the inlet line.
Purging: The act of replacing air with fl uid in a fl uid power system by forcing fl uid into all of the components and allowing the air a path of escape.
Rated Flow: The maximum fl ow that the power supply system is capable of maintaining at a specifi c operating pressure.
Scoring: Scratches in the direction of motion of mechanical parts caused by abrasive contaminants.
Swash Plate: A mechanical device used to control the displacement of the pump pistons in a fl uid power system.
System Charge Check Valve: A valve controlling the replenishing fl ow of fl uid from a charge circuit to the closed loop in a fl uid power system.
System Pressure: The pressure which overcomes the total resistance in a system, including all effi ciency losses.
Valve: A device which controls fl uid fl ow direction, pressure, or fl ow rate.
Variable Displacement Pump: A pump in which the displacement per revolution can be varied.
Volumetric Displacement: The volume for one revolution.
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39
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
40
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T2
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
T2 ®
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41
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
© 2008 HYDRO-GEAR
Printed in U.S.A.
Rev. P2 www.mymowerparts.com
