For Husqvarna Parts Call 606-678-9623 or 606-561-4983
SECTION 5. REPAIR
HOW TO USE THIS SECTION TRANSAXLE REMOVAL
Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly
instructions only. See pages 32 and 33 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of this section.
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.
It is necessary to remove the 310-2400 from the vehicle before performing the repair procedures presented in this section. Use the following procedure to prepare the unit for removal from the vehicle.
1. With the vehicle wheels on the ground, loosen the ¾-16 hex nut (108, Figure 12)
Page 21, if so equipped. Use an air impact wrench and a 1-1/8” socket to loosen the nut.
GENERAL INSTRUCTIONS
2. Lift the vehicle wheels off the ground and remove the nut completely.
3. Remove the wheel from the hub.
4. Using a wheel or gear puller, remove the hub from the shaft.
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.
Parts requiring replacement must be replaced from the appropriate kits identified in the Items
Listing, found at the end of this manual. Use only original Hydro-Gear replacement parts found listed in BLN-50937 (microfiche) or
BLN-51427 (CD).
CAUTION
USE CARE IN REMOVING THE HUB TO
PREVENT CRACKING.
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
28.
14 310-2400 IZT www.mymowerparts.com
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
TOOLS AND TORQUES
Miscellaneous
310-2400 Service & Repair Manual
Flat Blade Screw Driver
Torque Wrench
Air Impact Wrench
Rubber Mallet
Pliers
Needle Nose
Large External Snap Ring
Small External Snap Ring
Large Internal Snap Ring
Table 4. Required Tools
Sockets
3/8"
1/2"
7/16"
9/16"
E-8 Torx Head
Wrenches
1/2"
Table 5. Required Torque Values
Operation U.S. Torque Metric Torque Item Description
Wheel Hub Nut 200-295 ft-lbs 271-400 Nm 108 Nut, Hex 3/4-16
Fan/Pulley Nut 360-520 in-lbs 41-59 Nm 49 Nut, Hex Lock 1/2-20
Back Cover Screws 110-150 in-lbs 12-17 Nm 50 Screw, 1/4-20
Friction Pack Stud 50-120 in-lbs 6-14 Nm 36 Stud, 5/16-24
Control Arm Nut 180-240 in-lbs 20-27 Nm 35 Nut, 5/16-24
Control Bolt 192-252 in-lbs 22-28 Nm 76/121 Nut/Bolt, 5/16-18
Brake Yolk Screw 80-120 in-lbs 9-14 Nm 123/211 Screw, 1/4-28
Cog Brake Arm Screw 110-150 in-lbs 12-17 Nm 123 Screw, Hex 1/4-20
Check Plug Assembly 200-360 in-lbs 23-41 Nm 45 Check Plug Assembly
Lower Housing Screw 110-150 in-lbs 12-17 Nm 50 Screw, 1/4-20
Center Section Screw 525-700 in-lbs 59-79 Nm 44 Screw, 3/8-24
Lock Down Screw 210-270 in-lbs 24-30 Nm 208 Screw, 5/16-24 (Lock-Down)
310-2400 IZT 15 www.mymowerparts.com
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
BACK COVER
Refer to Figure 8. ASSEMBLY
DISASSEMBLY 1. Apply sealant to the back cover (1). Refer to page 29.
1. Remove the eight screws (50) from the back cover (13), and discard.
2. Remove the back cover (13). Take care not to damage the casting surfaces.
3. Clean off the sealant from the mating surfaces of the back cover (13) and the main housing assembly (1).
2. Place the back cover (13) onto the main housing assembly (1).
3. Install the eight replacement screws (50) to secure the back cover (13) to the main housing assembly (1). Tighten the eight screws (50) to the torque value listed in
Table 5.
INSPECTION
1. Inspect the back cover (13) for excessive wear or damage.
50
13
16
1
Figure 8. Back Cover Assembly www.mymowerparts.com
310-2400 IZT
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
BRAKES
(Cog Brake)
Refer to Figure 9.
DISASSEMBLY
1. Remove the external retaining ring (63).
2. Remove the brake bolt (123), brake arm
(70) and brake disc (73). Note the orienta- tion of the hub on the brake disc.
INSPECTION
1. Inspect the brake disc (73) for damaged splines or gear teeth.
2. Inspect the brake arm (70) for damaged teeth.
ASSEMBLY
1. Insert the brake shaft (55) into the main housing (1). Slide the brake disc (73) onto the brake shaft (55). Note the orientation of the brake disc. The hub on the brake disc should face inward on R.H. units and outward on L.H. units.
2. Install the brake arm (70) and brake bolt
(123) onto the main housing (1). Tighten the brake bolt (123) to the torque value listed in
Table 5.
3. Install an external retaining ring (63) onto the brake shaft (55).
55
310-2400 IZT
63
73
1
123
70
Figure 9. Cog Brake Assembly www.mymowerparts.com
17
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
BRAKES
(Disc Brake)
ASSEMBLY
Refer to Figure 10.
DISASSEMBLY
INSPECTION
1. Remove the cotter pin (128) and slotted hex nut (133). Discard the cotter pin.
2. Remove the washer (19), brake arm (70), compression spring (130) and brake actuating pins (129).
3. Remove the three brake yoke screws (123).
Remove the brake yoke (131).
4. Remove the stators (127) and rotor (73).
1. Inspect the brake components for excessive wear. Replace if necessary.
1. Slide the stators (127) and rotor (73) onto the brake shaft (55, Figure 11). Pay close attention to the stack up of the stators and rotor.
2. Install the brake yoke (131) with the three brake yoke screws (123) onto the main housing (1). Refer to Table 5 for the required torque.
3. Install the brake actuating pins (129) and compression spring (130) onto the brake yoke (131).
4. Install the brake arm (70), washer (19) and slotted hex nut (133) onto the brake yoke
(131). Do not tighten the slotted hex nut
(133) at this time.
5. Insert a .020" (0.5 mm) feeler gage between the brake rotor (73) and outer stator (127).
Adjust the brake by tightening or loosening the slotted hex nut (133).
6. Install a new cotter pin (128) to secure the slotted hex nut (133).
127
18
127
130
70
129
19
73
133
128
131
123
Figure 10. Disc Brake Assembly www.mymowerparts.com
1
310-2400 IZT
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
BRAKE SHAFT & BEVEL GEAR
Refer to Figure 11. INSPECTION
DISASSEMBLY
1. Remove the back cover. See page 16.
1. Inspect the brake shaft (55), ball bearing
(26) and bevel gear (52) for wear or damage.
2. Remove the brake. See pages 17-18.
ASSEMBLY
3. Remove the brake shaft lip seals (58) and retaining rings (126). Discard the lip seals
(58).
1. Insert the brake shaft (55) and ball bearing
(26) into the main housing (1) allowing the brake shaft (55) to pass through the 19 tooth bevel gear (52). 4. Remove the retaining ring (67) from the outside of the ball bearing (26).
2. Install the retaining ring (67).
5. Remove the brake shaft (55) and ball bearing (26) from the 19 tooth bevel gear
(52). It may be necessary to tap lightly on the brake shaft (55) to remove the bearing
(26).
3. Install the brake shaft lip seals (58) and retaining rings (126).
4. Install the brake. See pages 17-18.
5. Install the back cover. See page 16.
6. Remove the 19 tooth bevel gear (52).
55
67
126
26
58
58
310-2400 IZT
126
52
1
Figure 11. Brake Shaft & Bevel Gear Assembly www.mymowerparts.com
19
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
AXLE SHAFT & SPUR GEAR
Refer to Figure 12. ASSEMBLY
DISASSEMBLY
1. Remove the back cover. See page 16.
2. Remove the brake. See page 17-18.
3. Remove the brake shaft and bevel gears.
See page 19.
4. Remove the hub assembly (107), if not already removed.
Note: The orientation of the hub and axle to the main housing is critical in reassembly.
5. Remove the retaining ring (68) from the outside of the axle shaft seal (66).
1. Place the spur gear (53) and axle bushings
(81&82), per noted orientation, into the main housing (1).
2. Insert the axle shaft bearing (64) and axle shaft (56) into the main housing (1).
(A clean screwdriver may be used to help align the gear and bushings during installation).
3. Place the axle retaining ring (62) onto the end of the axle shaft (56).
4. Using a rubber or plastic mallet, lightly tap a new side seal plug (60) into the main housing (1). Install the seal plug retaining ring (68).
6. Remove the axle shaft seal (66) and discard.
5. Slide the axle shaft bearing (65) onto the hub end of the axle shaft (56).
7. Remove the retaining ring (68) from the outside of the side seal plug (60).
8. Remove the side seal plug (60) by lightly tapping on the end of the axle shaft (56) with a plastic or rubber mallet. Discard the side seal plug (60).
9. Remove the axle shaft retaining ring (62) from the axle shaft (56).
6. Slide the axle seal (66) onto the axle shaft
(56). Remember to protect the seal (66) during installation by covering the axle shaft
(56) with cellophane. Remove the cellophane once the seal (66) is installed.
7. Install the retaining ring (68).
10. Remove the axle shaft (56) from the main housing assembly (1). Remove the ball bearings (64 & 65) from the axle shaft (56).
Note the orientation of the axle shaft bushings (81 & 82). This is important for reassembly. Remove the two axle shaft bushings (81 & 82) and spur gear (53) from the inside of the main housing (1).
8. Install the hub assembly (107) and nut (108) with the bolt threads facing away from the transaxle.
9. Install the brake shaft and bevel gear. See page 19.
10. Install the brake. See pages 17-18.
11. Install the back cover. See page 16.
INSPECTION
1. Inspect the ball bearings (64 & 65) and axle shaft (56) for wear or damage.
2. Inspect the spur gear (53) for wear or damage.
20 310-2400 IZT www.mymowerparts.com
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
AXLE SHAFT & SPUR GEAR
82
53
81
1
65
68
56
66
108
107
Figure 12. Axle Shaft & Spur Gear Assembly
62
68
64
60
310-2400 IZT www.mymowerparts.com
21
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
LOWER HOUSING & FILTER
Refer to Figure 13.
DISASSEMBLY
ASSEMBLY
1. Install a new filter (46).
1. Remove the ten screws (50) holding the lower housing (2) to the main housing (1), and discard.
2. Remove the lower housing (2) and old sealant. Take care not to damage the casting surfaces.
3. Remove and discard the internal filter (46).
2. Apply sealant to the lower housing (2) where the lower housing (2) mates with the main housing (1). Refer to page 29.
3. Place the lower housing (2) on the main housing (1).
4. Install the ten replacement screws (50) that hold the lower housing (2) to the main housing (1).
INSPECTION
1. Inspect the lower housing (2) for excessive wear or damage.
5. Torque the ten screws (50) to the value listed in Table 5.
22
1
50
Figure 13. Lower Housing & Filter www.mymowerparts.com
46
2
310-2400 IZT
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
MOTOR SHAFT & BEVEL GEAR
Refer to Figure 14. ASSEMBLY
DISASSEMBLY
1. Remove the back cover. See page 16.
2. Remove the brake. See pages 17 & 18.
1. Install the motor shaft (54), bearing assembly (26) and wire retaining ring (27). Note:
The splines must be aligned when insert-
ing the motor shaft (54).
3. Remove the brake shaft & bevel gear.
See page 19.
2. Install the 14 tooth bevel gear (51) on the end of the motor shaft (54).
4. Remove the axle shaft & spur gear.
See pages 20 & 21.
3. Install the axle shaft and spur gear. See pages 20 and 21.
5. Remove the 14 tooth bevel gear (51) from the motor shaft (54).
4. Install the brake shaft and bevel gear. See page 19.
5. Install the brake. See pages 17 and 18.
6. Remove the motor shaft (54), wire retaining ring (27) and bearing assembly (26) from the main housing (1). Note: The bearing
(26) does not fit flush with the housing.
This is important for reassembly.
6. Install the back cover. See page 16.
INSPECTION
1. Inspect the gear (51), shaft (54) and bearing
(26) for wear or damage.
1
310-2400 IZT
27
51
26
54
Figure 14. Motor Shaft & Bevel Gear Assembly www.mymowerparts.com
23
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
CENTER SECTION, CYLINDER BLOCKS AND BYPASS
Refer to Figure 15.
DISASSEMBLY
1. Remove the back cover. See page 16.
2. Remove the brake assembly. See pages 17 and 18.
3. Remove the brake shaft and bevel gear.
See page 19.
4. Remove the axle shaft and spur gear. See pages 20 and 21.
5. Remove the lower housing and filter. See page 22.
6. Remove the motor shaft and bevel gear.
See page 23.
7. Remove the three screws (44) holding the center section (3) to the upper housing (1).
Lift to remove the center section (3) and motor cylinder block assembly (21). Remove the two pins (43).
8. Remove the motor cylinder block assembly
(21).
9. Remove the motor block thrust bearing assembly (25). Note: The thick race is lo- cated nearest to the pistons when as-
sembled properly.
10. Remove the pump block assembly (15).
11. Remove the pump block spring (14), washer (24) and swashplate assembly
(10).
12. Remove the thrust bearing assembly (11).
Note: The thick race is located nearest
to the pistons when assembled prop-
erly.
13. Remove the slot guide (30, Fig. 16).
14. Remove the bypass arm retaining ring (42), bypass arm (41) and bypass lip seal (40).
Discard the lip seal.
INSPECTION
1. Check the pistons in the motor and pump blocks for free movement.
2. Remove and inspect the pistons, springs and seats for wear or damage.
3. Inspect the piston bores in the cylinder blocks for wear or damage.
4. Check the running surface of the motor and pump cylinder blocks for damage. This surface must be smooth in the three sealing areas. Reassemble the motor and pump cylinder block assemblies and set aside.
5. Inspect the bushing in the center section and the by-pass plate (38).
6. Check the motor and pump cylinder block running surfaces on the center section (3).
This surface should be smooth. Drag a fingernail across it to detect scratches or smearing.
7. Inspect the thrust bearing assemblies (11 and 25) for wear or damage.
ASSEMBLY
1. Install a new bypass lip seal (40). Install the bypass arm (41) and retaining ring (42) onto the bypass actuator (39).
2. Install the slot guide (30, Fig. 16).
3. Install the swashplate assembly (10)
(including the thrust bearing assembly).
Note: Install the thrust bearing assembly
(11) with the thick race towards the pis-
tons.
4. Actuate the trunnion arm (31) and swashplate (10) to verify free movement.
5. Install the pump block washer (24) and spring (14).
6. Install the pump block assembly (15).
7. Center the by-pass actuator (39) in the housing pocket.
24 310-2400 IZT www.mymowerparts.com
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
CENTER SECTION, CYLINDER BLOCKS AND BYPASS
8. Install the two pins (43).
9. Install the by-pass plate (38) into the center section (3). Install the center section (3) and motor cylinder block assembly (21).
13. Install the filter and lower housing. See page 22.
14. Install the axle shaft and spur gear. See pages 20 and 21.
15. Install the brake shaft and bevel gear. See page 19.
10.Install the three screws (44) that hold the center section (3) in place.
11.Install the thrust bearing assembly (25).
Note: Install the thrust bearing assembly
with the thick race towards the pistons.
12. Install the motor shaft and bevel gear. See page 23.
16. Install the brake. See pages 17 and 18.
17. Install the back cover. See page 16.
42
41
40
310-2400 IZT
31
1
39
10
11
24
38
43 14
15
25
3
21
43
44
Figure 15. Center Section, Cylinder Blocks and Bypass www.mymowerparts.com
25
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
INPUT SHAFT & TRUNNION ARM
Refer to Figure 16. ASSEMBLY
DISASSEMBLY
INSPECTION
1. Install the trunnion arm (31) if removed and install a new trunnion seal (33).
1. Remove the back cover. See page 16.
2. Remove the brakes. See pages 17 and 18.
3. Remove the brake shaft and bevel gear.
See page 19.
4. Remove the axle shaft and spur gear. See pages 20 and 21.
5. Remove the lower housing and filter. See page 22.
6. Remove the motor shaft and bevel gear.
See page 23.
2. Install the slot guide (30).
3. Install the input shaft (12), bearing assembly (8) and wire retaining ring (6), if removed.
4. Install the spacer (5).
5. Install a new input shaft lip seal (4). Remember to protect the seal during installation by covering the shaft with cellophane.
7. Remove the center section and cylinder block assemblies. See pages 24 and 25.
8. Remove the input shaft retaining ring (7).
9. Remove and discard the lip seal (4).
6. Install the input shaft retaining ring (7).
7. Install the center section and cylinder block assemblies. See pages 24 and 25.
8. Install the motor shaft and bevel gear. See page 23.
9. Install the lower housing and filter. See page 22.
10. Install the axle shaft and spur gear. See pages 20 and 21.
10. Remove the spacer (5).
11. Remove the input shaft (12) and bearing
(8).
12. Remove the slot guide (30).
13. Rotate the trunnion arm (31) to check for free movement.
14. Remove the trunnion shaft seal (33) if necessary and remove the trunnion arm
(31).
11. Install the brake shaft and bevel gear. See page 19.
12. Install the brakes. See pages 17 and 18.
1. Inspect the input shaft (12) and bearing (8) for wear or damage.
2. Inspect the slot guide (30).
13. Install the back cover. See page 16.
3. Inspect the trunnion arm (31) for wear or damage.
4. Inspect the non-removable cradle bearings
(9) in the main housing (1) for excessive wear.
26 310-2400 IZT www.mymowerparts.com
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
INPUT SHAFT & TRUNNION ARM
4
6
7
5
8
310-2400 IZT
33
1
9
Note: Cradle bearings are nonremovable. Shown removed for illustration purposes only.
12
Figure 16. Input Shaft and Trunnion Arm Assembly
30
31 www.mymowerparts.com
27
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
TRANSAXLE INSTALLATION ASSEMBLY AFTER A COMPLETE
TEARDOWN
Use the following procedure to complete the installation of the transaxle on the vehicle.
1. Install and secure the transaxle on the vehicle according to the instructions in the vehicle owner’s manual.
2. Install the hub assembly (107, page 21) if not already done. Install the ¾-16 hex nut
(108, page 21).
3. With the vehicle raised, install the wheel on the hub, and snug the wheel lug nuts.
4. Lower the vehicle wheels to the ground and torque the ¾-16 hex nut to 200-295 ft.-lbs.
(271-400 Nm).
5. Tighten the wheel lug nuts per the vehicle owner’s manual.
If the unit has been torn down completely, the following summary identifies 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 exploded views, and are also keyed to the complete unit exploded view on page 30.
1. Install the input shaft and trunnion arm. See page 26.
2. Install the center section, motor and pump cylinder blocks. See page 24.
3. Install the motor shaft and bevel gear. See page 23.
4. Install the filter and lower housing. See page 22.
5. Install the axle shaft and spur gear. See page 20-21.
6. Install the brake shaft and bevel gear. See page 19.
7. Install the brake. See pages 17 and 18.
8. Install the back cover. See page 16.
9. Fill the transaxle with 79 fluid ounces
(2336 ml.) of new 20w50 motor oil. This should put the oil level approximately
1? " (48 mm) from the top of the housing.
This should be checked at the fill port.
10. Install the transaxle onto the vehicle.
11. Perform the purge procedures listed on page 11.
12. Perform the return to neutral procedure on page 12.
28 310-2400 IZT www.mymowerparts.com
