PEERLESS TECUMSEH PRODUCTS COMPANY setae, oh Bly, wost® ENGINE DIVISIONS - GRAFTON, WISCONSIN 53024 WHERE IMAGINATION AND INNOVATION FORM 691218 HELP SHAPE AN INDUSTRY LITHO IN USA. GENERAL INFORMATION TRANSMISSIONS 600 TRANSAXLES 1200, 1400, 1700,2000 THREE - SPEED TRANSAXLES FOUR - SPEED TRANSAXLES 1300 REDUCTION GEAR “AND DIFFERENTIAL UNIT, 2400 AND 2500 REDUCTION GEAR AND DIFFERENTIAL UNIT, DIFFERENTIALS DRIVES SHIFTING ASSEMBLY BEARING AND BUSHING SERVICE~ ~~ PEERLESS MECHANIC’S HANDBOOK TABLE OF CONTENTS Section 1 GENERAL INFORMATION. «se 0+ Ay How to Use This Manual + Peerless Products ~ General - G. dentiftention of Models. D. Terms Used..... 5 BE, Lubricant Capacities and Types | F. General Service Procedures... G. Oil Leaks, Seal and Gasket Service H. Torque Values ~ Trouble Shooting 1 Testing TRANSMISSIONS ...1... A. General B. Disassembly .. C. Inspection and Repair « D. Assembly... ‘TRANSAXLES - 3-SPEED ALUMINUM CASE (600 SERIES)... As General ve... sse B. Disassembly... CL Assembly... ‘TTRANSAXLES - 3-SPEED CAST IRON CASE (1200, 1700, AND 2000 SERIES) AL General . B. Disassembly » ©. Inspection and Repair... D. Assembly... TRANSAXLE - 4-SPEED (2300 SERIES)... A. General | BL Disassembly». C. Inspection and Repair D. Assembly... REDUCTION GEAR AND DIFFEREN- TIAL UNITS - ALUMINUM CASE .. - A, General (1300 Series) «2.2.1. BL Pre-Disassembly . « G. Disassembly . D. Inspection and Repair... E. Reassembly .. REDUCTION GEAR AND DIFFEREN- TIAL UNITS . A, 2400 Series... si litcseseee (1) Disassembly. 2 (2) Inspection and Repair « (3) Assembly... 0. ee. () Separating and Combining Hydrostatic Unit and 2400. . Section 10 ry B. 2500 Series... () General - . 2° (2) Broparaticn tor bisasseimiy (3) Disassembly . (4) Inspection and Repair « (3) Assembly... (8) After Assembly DIFFERENTIALS. A. General... ss... qi B. 100 Series Differential . ¢ (1) Disassembly . . @) Reassembly +. C, 600 Series Differential + (1) Disassembly, Inspection, and Repair.’ es sees eee (2) Reassembly and Test « 1200, 1300, 1700, 2000, 2300, and 3400 Series Differentials | . . Disassembly, Inspection, and Repair sss sees ees Reassembly and Test - E. Limited Slip Differential . () Operation... (2) Disassembly, Tnspecion, and Repair... (8) Assembly and Test DRIVES - RIGHT ANGLE AND "I". A. General Disassembly, Inspection, a an Repair « . C. Assembly and Test: SHIFTING ASSEMBLY .. A. Shift Patterns... B, shift Lever Assembly 1... (a) Doweled Type Repair « (b)_ Snap Ring Type Repair C. Shifting Assembly .... (@Q) General... 0 2) Disassembly, Inspection, and Repair... () Assembly 272121 BEARING AND BUSHING SERVICE . . ‘A. General Bearing and Bushing Care .. B, Ball Bearing Service’ +! C. Needle Bearing Service. D. Bushing Service ... Ut Mt uw el 11-2PEERLESS MECHANIC'S HANDBOOK Introduction SECTION 1 GENERAL INFORMATION ‘A. HOW TO USE THIS MANUAL 2, How does the shift lever conform to the 1, GENERAL. ‘The purpose of this handbook 48 to give up-to-date care, service, and repair instructions for Tecumseh's Peer Jess Division products. By following this handbook, a better, fast er, more profitable method of servicing Peerless products can be attained. 2. USE. Usethis handbook with the pertinent Divisions of the Master Parte Manual. ‘The Parts List will show the exact parts for any Peerless unit. ‘This handbook points out procedures and methods for the proper repair or adjust~ ‘ment of parts according to factory recom- ‘mendations. 3, TABLE OF CONTENTS. Usethe Table of Contents whenever you are in doubt as to ‘where to look for servicing information. 4, BEFORE REPAIR. Read the section per- {taining to the unit being repaired (usually 4-6 pages or less). Complete understand ing of what you will do will eliminate time consuming errors and rework. 5. REPAIR. Disassemble the unit in an or- derly fashion. Lay disassembled parts out so that a clear pattern of reassembly is apparent, Use scribe marks on axle hous- ‘ng, shift lever housings, etc. Be aware of bevels on gears and how they are posi- tioned. Give the unit definite area relation ships, such as down, up, leit, right, etc. By working carefully with units until ex- perience takes over, good working prac- Hees will become habit, 6, REASSEMBLY. Every parthasa purpose. ‘Try to explain ‘the purpose to yourself as you put the parts together. The value of ‘the orderly lay out of parts will be made clear at this time. Use the Master Parts ‘Manual, if in doubt as to proper sequence of parts. It can save valuable time later on by not having to tear the unit down to Sind a "built-in" mistake. Shift Lever Housing 1, Is there a mark on the housing? unit? ‘Make scribe marks if in doubt as to how ‘the unit will be re-assembled. Case and Cover 1. Do remove the case from the cover? On all units except the 2300 and 2400, re- move the cover from the case. 2, How do T distinguish the case from the cover? ‘The cover has the brake shaft extension, ‘while the case has the inputshaft and shift tower as applicable. (Does not apply to 600 series, in which the case is apparent.) ‘Thrust Washers and Shafts 1, Do know towhich shaft and to which side each thrust washer will assemble? 2, Do I know which end of each shaft goes into ‘the case or cover? Gears 1, Are bovels identified and do I know which ‘way they face? ‘The purpose of the bevel on the tooth is to allow easier meshing of shifting gears. ‘Therefore, the bevel must fall in the dic rection the gear meshes ‘The outside gears on a three gear cluster are near the edges of the case and cover, therefore meshing must come from away from the case and cover. B. PEERLESS UNITS 1. GENERAL Peerless makes power transmission ac- cessories for use in all types of lawn and garden equipment. "TRANSAXLES ‘A combination of familiar parts of a drive ‘rain, the transmission and differential ‘axle, inone compact unit. Peerless trans— andes are of various speeds forward units ‘with one speed in revers (a) 600 Series. ‘The 600 series units are considerable different from all otherlotroduetion 12 wo @ PEERLESS MECHANIC'S HANDBOOK Peerless transaxle series, both in designandappearance, The 600 series is a lightweight unit usually used in riding mower or similar application. ‘The 600 series has a vertical input shaft at the top Of the case. The case is aluminum, contributing to a con~ siderable weight saving. Variations in the series (which deter- ‘mines the specific model number such as 603, 808A, 608, etc.) includes: (1). shite ever shape. (2) Axle lengths. (8) ‘Axle machining forwheel hub at- tachment. (4) Axle housing variations. (8) Size of the brake shatt. ‘There may be other slight differences, however, these are present as a re- sultof product improvement whichare not options to an O.E.M. (Original ‘Equipment Manufacturer). NOTE: ‘The transazles described in paragraph (0), (), (d), and (e), below are fairly similar in appearance, but do have specific recognizable charac- teristics. All these unite have cast iron bodies for rugged application, although the 2300 series only can be used in ground engaging equipment applications. 1200 Series. The distinguishing fea~ ture of the 1200 series transaxies is that the axde support housings are pressed from the inside of the case and cover, therefore, are not readily Femovable until theunit is completely. disassembled. The casing is cast iron for rugged, long-time wear. The Anput shaft extends horizontally through the case while the larger brake shaft extends through the caver on the opposite side. The shift lever housing attaches to the ease, ‘A basic difference within the 1200 Series itself is that tig input can be either right or left depending upon equipment application, therefore, the case can be either the left hand or right hand "halt" of the casing, de- ending upon the application. ‘This, along with the variations listed for the 500 series ( (a) above) determines the model number within the 1200 series basic type. 1700 Series. ‘The'1700 design closely {ollows the 1200 series except that the axle support housings bolt to the case and cover and are removed prior to disassembly of the case and cover. (@) 2000 Series. Theseunits aresimilar to the 1700 series except that theaxle support housing contains sealed ball bearings rather than bushings. Other aifferences are apparent internally ‘which will be deseribed in the tear- down procedure of these units. (@) 2800 Series. Generally similar to the 2000 series transaxle, The dis- tnguishing featuresare 2 more mas- sive easing, and a shift opening ma~ chined area that is larger. The obvious difference trom the standpoint of ap- Plication is that these units are four Speed forward and will be found on equipment that can beused for ground engagement operations. 3. REDUCTION GEAR AND DIFFERENTIAL ‘UNITS GENERAL ‘These units do not have a transmission function characteristic of transaxles, but rather, are units to reduce input speed ‘and torque to 2 suitable axle speed and (torque. The hydzostatieunits which maten to these units perform the transmission function by the use of one control lever to the operator. (a) 1900 Series. ‘This unit is the hydro- Static counterpart of the three-speed forward units (1200, 1700, and 2000), Ithas analuminum casingand pressed through axle support housings, char- Acteristie of the 1200 series. ‘The hydrostatic unit is of Eaton, Yale, ‘Towne manufacture and isnot serviced by Tecumseh Service Dealers. (0) 2400 Series. ‘This series of hydro- Statically driven reduction gear and fifforential unit can be used inground engaging operations such as plowing. ‘The hydrostatic unit is manufactured by Sundstrand Corp. in LaSalle, Il, 4. TRANSMISSIONS ‘These units as manufactured by Peerless ‘consist of the shifting mechaniam to take constant input shaft speed and reduce it to the desired output speed. The differen- al or axle unit is connected through & chain drive, C,5 PEERLESS MECHANIC'S HANDBOOK (@) 350’ Series. ‘This 3-speed forward, Lspeed reverse transmission has a feast aluminum casing. Tt uses the ‘same ahift lever housing forward on the 600, 1200, 1700, and 2000 series transaxles. Bronze sintered bushings fare porous, allowing for a lubricant flow through them. () 400 Series. This unit is like the 950 unit except the caged needle bearings replace bushings at the input and out put shafts. DIFFERENTIALS ‘The only self contained differential/axle unit built by Peerless is the 100 serie It features hardened axle shafts of various length and machined for various methods of hub attachment. ‘The case{s castalumi- numand the differential gears are sintered etal. The differential pin isheld securely fm place by the four retaining capscrews Ollite bushings reduce friction during dif- {erential operation. ‘The drive sprocket is part of the unit, D pending upon application, it can be in any Of several diameters in size, thus having a different number of gear teeth. ANGLE DRIVES ‘These units are used primarily to change the direction of power transmission at the point where the working equipment at- taches. ‘They can be assembled for right or left hand rotation so that they can be used in various combinations for synchronous op- eration. (a) Right Angle Drive. These units con- ‘sistof input shafts, output shafts, and the beveled gearing necessary to change the direction of power trans- ‘mission at right angles. By position {ing the drive bevel gear on the input shaftnearest the input end the opposite rotation will be attained from that of switehing the beveled gear around to ‘the sideaway from the input end of the shaft. Casing and bearings are identical. Acover identifies each unit as being either a left hand (LH) ora right hand (RH) right angle drive. (0) "T" Drives. The "T" driveis essen- tially the same as the right angle Introdution drive except that the input shaft is ex- fended out through the other side of the ease totransmit power in the same Une toadditional right angle drives or other equipment. (©) Shafts, Couplings, Pulleys, etc. These Meme are part of the total trans~ mission unit and are sed to connect angle drives, and other attachments. ‘The serrated couplings match serra~ tions on shafts of the angle drives or fon connecting shafts. ¢. IDENTIFICATION OF MODELS Since acquisition by Tecumseh Products Co. in1064, all Peerless assemblies havea model number identification tag, or stamping. ‘On units containing axles (transaxles, or re- duction gear and differential units) the iden- tification should be visible by viewing the ease/cover unit from below and behind as it is mounted in the driven equipment. Ir the area is dirt or oll covered, however, some cleaning may benecessary. Write down any numbers found in locations pointed out in Figure 1-1, then compare with the Master Parts Manual Div. 8 index. For right angle and'"T" drives, the identifi ‘cation number is stamped into the housing tunder the input shaft boss opposite the cover. On transmissions the identification number is stamped on the cover back of the output drive sprocket. On the 100 series differential, the number is stamped either on cast housing diameter or fon the housing end near the axle bushing. D, TERMS USED Understanding certain terms is important since {t is the key tounderstanding this man- ual, Some terms may be of no importance to all units, but, working with all units, will Show the necessity of having them defined. ‘These items as defined here, pertain to these Peerless instructions, and are not to be con- Strued with similar ferms in other instruc- tions, or in general usage if a conflict in definition arises. AXLE - The shaft which connects the wheel ‘of hub to the differential unit and tran nitsforce back to the wheels. Sometimes axle refers to the differential and axle combination as in the term TRANSAXLE. vaIntroduction PEERLESS MECHANIC'S MANUAL. Soo SERte é a oo series fo Individual Serial Number Manufactured on the 275th Day Manufactured in 1973 Early models were not identified with a model number on the unit ‘THE MODEL NUMBER WILL BE FOUND ON: A. Metal tag attached to unit as illustrated. Stamped on unit as illustrated, 14 Figure 1-1, [dentification Number Locations 1/74 Litho in U.S.A,PEERLESS MECHANIC'S HANDBOOK Introdvetion AXLE HOUSING (or AXLE SUPPORT) - An ‘extension of the caseand cover to support the outer ends of the axles. Because the hhowsing is visible, it is often the best means of distinguishing the series in question. BEVEL (on a gear ~ different from bevel ‘gear) - Roundness of the meshing sides of gear tecth toallow easy shifting. Becanse this is about the only allowance made to ‘make easier shifting, the unit should be ‘Stopped before the shift to keep these spur gears from getting chewed up. BEVEL GEAR - A gear with teeth ground on ‘diagonal so that when it meshes with a Second bevel gear, power is transmitted at an angle. If the angle is 90°, the gear 4s known as a MITER GEAR. BEVEL PINION ~ The smaller of two meshed bevel gears in a gear train. BRAKE (or BRAKESHAFT) - That shaft on a ‘Peerless unit (Transaxies and Transmis- ‘sion) to which a braking system may be attached. ‘The shaft is in the gear train ‘with the differential to stop it when the operator "brakes". It is usually larger in diameter than the input shaft due to its function of taking shock loads experienced in braking. CASE - That part of the unit "casing half" ‘which contains the shift lever and input shaft openings. The other "half" is the COVER because the re-assembly must be done into ove or the ether depending upon CHAMFER - Diagonal milling at the comers of gear teeth to remove sharp edges. The ‘usual reason for chamfer to eliminate the possibility of hardened gears chewing soft- er metal. COUPLING - Asleeveto connect two serrated shafts in the same axial plane. Used in Tight angle drive systems or in connecting the hydrostatic drive to the input shaft on 2400 series transaxles, COVER - That part of the unit "casing half” which contains the brake shaft opening (except the 600 series in which all openings are in the CASE as described in CASE ~ above). The case and the cover switch sides depending upon whether the trans- axle is right or left hand drive. DIFFERENTIAL GEAR BOLTS - Through bolts holding the differential parts together. ‘The heads of these bolts must be opposite the output shaft gear (except in the 2400 ries). Thisis anearly check tosee that the unit is being assembled correctly. DOWEL PIN ~ Alignment pin used toalign the ‘case and cover and other partsin a trans- mission or transaxle. The dowel should be tapped in to hold the parts in alignment before tightening the retaining screws. Failure 1 install dowel pins first will usually lead to a unit that binds after assembly. DUO-TRAK* DIFFERENTIAL(* Trademark - ‘Linois Tool Works) ~ A type of differential which increases torque to the tractive ‘wheel to keep it turning, however, in sit~ uations where differentiation is necessary (as in turning) the unit acts much like a regular differential. EQUIPMENT - The complete assembly built ‘by a manufacturer, a part of which is the Peerless unit (riding mower, tractor, ete.). A check of the equipment manual is recommended prior to servicing the Peerless unit. HEAD ASSEMBLY-A COMPLETE UNIT CON- ‘TAINING ALL PARTS OF ONE right angle or "I" drive assembly of a right angle drive system. ‘The head assembly is per- manently lubricated and sealed. IDENTIFICATION NUMBER - See MODEL NUMBER. IDLER - A gearused inagear train totrans- fer mation or direction. The gear rotates independently of shaft upon ‘which it $5 located. INPUT or INPUT SHAFT - That part of a Peerless unit which is always connected to the drive. Its rotational speed is de- pendent on the driving mechanism. ALL parts of the input system are always in ‘mesh with input shaft and turn whenever ittums, LIMITED SLIP DIFFERENTIAL - See DUO- ‘TRAK* DIFFERENTIAL. MITER GEAR - One of a pair ot interchange- able bevel gears with axles at right an- gles, Since all bevel gears are miter ‘units, the terms can MODEL NUMBER - The identifying number ‘of a Peerless unit which will permit selec- 1sIniroduetion Ls ton of the proper parts torepair thatunit, See paragraph 1-C for locations of the ‘model number. OI SEAL, DOUBLE LIP - An ofl seal with ‘two sealing surfaces to prevent entrance of foreign matter, andleakage of lubricant. OIL SEAL, QUAD RING - Aseal with two ex- ternal and two internal sealing lips. Used in the shifter housing. OIL SEAL, SINGLE LIP - An ofl seal with ‘one sealing surface to either prevent en- trance of foreign matter or prevent leak- age of lubricant. OUTPUT, or OUTPUT SHAFT - On a trans- axle, ‘that shaft that contains the output inion which is in direct mesh with and drives the differential. In a transmission, the exposed shaft which contains the ‘sprocket for driving the axles. The out- put shait is driven by the large OUTPUT. Gea. OUTPUT SHAFT GEAR - The importance of defining this gear here is to point out that it must be opposite the differential bolts in Peerless units (except the 2400 series) ‘The output gear assembles into transaxle PEERLESS UNIT or UNITS - THE COM- PLETE PEERLESS assembly whichis part of the EQUIPMENT. ‘The Peerless unit is that assembly being described. REDUCTION GEAR AND DIFFERENTIAL UNIT - A PEERLESS unit that reduces a high RPM input speed toa suitable axle speed without useof atransiaiasion, Since there is a single gear train, there is a single input speed to output speed ratio, however, axle speeds are infinite, depend {ng upon input speed. REVERSE IDLER - A gear added to the gear train so that in mesh, it reverses the di- rection of all gears driven after it. Ite number of teeth also affects the reverse gear ratio. ‘The center gear of the three gear cluster always is in mesh with the REVERSE IDLER and the lange shifter gear always shifts into it. RIGHT ANGLE DRIVE - Interchangeable with HEAD ASSEMBLY. The major operating parts are a pair of miter gears, A sys- tem consists of other right angle or "T" drive head assemblies and connecting hardware. SEAL - A mechanism which stops leakage. PEERLESS MECHANIC’S HANDBOOK E can be a rubber ring, as an "O" ring or "quad ring, a sealing’ type ball bearing, oF most commonly, a rubber-like sealing Surface encased in a metal form, SBAL RETAINER - Found on some models of ‘transaxles and on right angle drives. The center of the retainer is bored to the size of the outer diameter of the seal. On transaxles the retainer acts to position the differential. In the casing on right angle drives, it aets as the end cap of the ease and is secured with four capscrews. SPROCKET - Ageared wheel designed toturn ‘link chain drive. Various numbers of teeth (hence, sprocket diameter) are avail- able to change output ratios. SPUR GEAR - A gear having the shaft bore and teeth ina parallel plane. A rugged, ‘economical gear. SHIFT LEVER - The lever by which the oper- ‘ator manually changes the shitter gears to vary reduction speed ratios In the trans- ‘mission. The configuration of the lever is ‘variable and is often the reason for a unit ‘being a particular model. SHIFTER FORK - A mochanical arm which ‘moves on rod to position the shifter gear atan exact spot axially along the shitter Shaft. SHIFTER GEAR, LARGE - This gear trans- ‘mits Ist (low) and reverse. (Ist, 2nd and Teversein 4-speed units) gear ratio force to the output shaft. It is beveled on both sides. SHIFTER GEAR, SMALL - This gear trans- ‘mits 2ndand rd (8rd and 4th ina 4-speed tunit) gear ratio foree to the output shaft, It can have two ditferent tooth diameters ‘and be beveled on the outside of each, or 4 can have a beveled spline to engage Sra (er 4th) gear through a splined shatt. SHIFTER HOUSING - The housing which re- tains the shift lever and when installed on the transmission case, both the lever in definite position relative to. the shifter forks. The housing should be seribe ‘marked upon removal to insure that it 1s re-installed so that the shift lever is in thr proper configuration, SHIFTER ROD - One of two similar smooth rods of equal length with grooves which ‘match the fork position to meshed po tions of the shifter geara and gears of the three gear cluster. Bach rod has a snap cPEERLESS MECHANIC'S HANDBOOK Ineroduetion| ring to act as a fork stop, but can also be Peencese LuanieaTiON used todetermine how the fork is assembl- ODER. aT ed to it. Same. suas SHIFTER SHAFT - A splined shaft which meshes with the internal splines of the shifter gears, to transmit forceto the out- rraeoe put shaft gear. | SHIFTER STOP - A stamped metal plate which \ Separates the shifter forks. The stop has notch cut in it which corresponds to the ante neutral position on the shifter forks and rod. The shifter lever must return the engaged fork back to neutral before it can cross to actuate the other fork. "T" DRIVE - A right angle drive with an input shaft extending thru the case to transmit ease power axially in a second direction to the right angle output, On "T" drive with dis- similar input and out endof the input shaft, care must be taken to insure that the parts aeteace do not run inreverse when re-assembled. | ‘THREE GEAR CLUSTER - A3gear assembly in mesh with the input shaft. The gears are of different, sizes to change in gear ratios when meshing with the two shifter gears. \ ‘THRUST RACE - A thrust washer h which the outer edge is cupped to fit the outer Slamoter of thrust ‘bearing. ‘This it positions the thrust race concentric with the axle diameter. it further acts asa thrust washer. ‘THRUST WASHER - A flat polished surface Separating metals of different hardness. It alsoacts as aspacer between shafts and the case and cover. sons TRANSMISSION - A system of varying sized \ ears in a case, some of which can be ‘slid along a shaftto vary gear ratio in the gear train. The net effect is to change T | ues fourencunass| tno romvs Speeds to the rear wheel according to the 201 ome ‘type of work being done. UNIT - See PEERLESS UNIT. | E, LUBRICATION CHART Check the Peerless unit model number before po {Alling with lubricant. ‘There may be a dit- 5 ference in the quantity recommended. This ie | isdletated by the designof the venicleand the LEE Litho in U.S.A. Revised 4/75 1-7Introduetion L GENERAL SERVICE PROCEDURES Introduction ‘The following service procedures should be undersiood and practiced whenever service ‘must be performed ona Peerless unit. Know- Ing time and will allow a constant check on repair status and thoroughness. Before removal of unit from equipment, Looie for: (a) Loose drive belts. (O) Improperly adjusted or badly worn clutch, (@) Loose or lost set screws and/or sheared keys in drive and driven pulleys, (q) OW saturated drive belts and clutches. (e) Bad operating habits, suchas clutch riding. (OW leaks. If found,” refer to 1-B. (@ Any trouble, which might be pointed up by operating theunit and equipment, IF POS- SIBLE. Removal of the Peerless unit from the equip» ment: (@) Jack upequipment so that transaxle is ac- essible. Use wood blocks to prevent equipment movement. Do not use bricks, cement, or cinder blocks. (#) Visually inspect Peerless untt for oil leaks, cracked housing,. binding or rubbing of Parts, or other symptoms of malfunction, (c) Usea jack under the Peerless unit to sup port its weight when attachments are re- moved. (@Remove wheels, drive belts, pulleys, chains and other associated equipment from Peerless unit, Be aware of position- ing.of parts. Seribe mark, if in doubt, a5 to abllity to re-assemble parts quickly. (@)If shifter lever will interfere with unit in any way, remove it before unitis removed. @ Remove attaching hardware holding Peor- lessunit toequipment at case, cover, axle supports, shifter, or by other means. (@)With Peerless unit tree and supported, remove it from the area of the equipment to the work bench. Preparing for dis-assembly: (a) Visually inspect for evidence of oil seep- age, tampering, misalignment, freedom of rotating sharts, etc. (0) Clean unit thoroughly of dirt, oil, debris. (c)Remove shift housing and drain oil fom unit. Observe oil tosee if metal particles are present. (@) Check axle ‘shafts carefully for amooth- fess. Use a stone or suitable hard abra~ sive to rub down high spots and eliminate PEERLESS MECHANIC'S HANDBOOK ‘ust oF paint. (e) Check model number at appropriate spot. It is advisable to have the exploded parts view handy: (® Have seal sleeves, driver, tools, shop clothes and informational material hand. G, OIL, LEAKS, SEAL and GASKET SERVICE Peerless units contain various styles and sizes of ‘il seals. The function f any oil seat can’bet 1, To seal inward (single lip) to prevent lu- bricant leaks. 2, To seal outward (single lip) to prevent Iubricant leaks. 8. To seal both inward and outward (double tp). Some seals,are spring loaded. ‘That ‘s, 2 spring creates a positive light compressing action to in sure that the seal lip will make 100% contact around ‘the shaft. AU Peerless seals, seal on the inner diameter. 1, Other than leaking seals;. gaskets and "0" rings, leakage.can occur.due to a cracked case ‘or cover, flats on shafts, porosity (rarely, if ever), and worn bushings and shafts. 2 Single Up inward sealing can be salvaged by uuse of the proper seal protector when pull ing the seal over a shaft, Outward sealing seal (both single and double lip) must be re= placed since there is'no assurance that the initial sealing surface can be protected. If you can't protect the sealing lip, replace the entire seal, The cost of the sealis small in comparison to.a return repair due to re- use for seals. Check seals for cracks, scuffs, cuts, and distortion. Check seal areas for evidence of oil leak both at sealing surface and between ‘metal-to-metal contact suriace areas. Some seals have a “Redicoat" sealant ap- plied, while others may need a thin coat of this ora similar sealant, 6. The surface over which the seal lips must slide must be free of all cuts, scratches, hhigh spots, or rust. ‘The shafts should be ‘smooth, shiny, and a thin film of Hight oil applied. Sleeves shouldbe used to clear key- ways, ‘splines, or other sharp edges ma- cchineld into shatts. c cPEERLESS MECHANIC'S HANDBOOK. H. TORQUE VALUES — TROUBLE SHOOTING 1. All torque values must be applied. The torque value for ‘any fastener will be found in the assembly instruction ‘where that fastener Is used. Differential Bolts 17s, ft, (ref. 6-6) “7 Drive Bolt BL Ibs. ft. “op” Drive Cover Serew 20-24 Ibs. in. 2, Overtightening — Can strip threads, compress the gasket excessively, possibly causing binding. 4. Undertightening 3. Crost tightening sequence to half the torque then finally to full torque valve. Oi leskage, loosening of attaching] hhifting of the internal part causing paris, possible complete failure, 5. Since all bolts are readily accessible there is no reason| that a torque wrench emmot be used for all bolt and serew tightening. To use guess or chance, eny of the revious.can result: TORQUE VALUE MODELS PART AFFECTED IN-LBS Fr-Lss| Bolt 5/16-18 (Housing) 1100 Series 19-22 Nut 5/16-18 (Housing) 100 Series 10-13 Bolt 1/4-20 (Case to Cover) 200 Series ‘SOTO, ‘Bolt 1/420 (Case to Cover) '350 Series ‘90-110 Bolt 1/4.20 (Shift Laver Housing 380 Series 84-108 ‘Bolt 1/4-20 (Case to Cover) “400 Series ‘90-110 Bolt 1/4-20 (Shift Lever Housing) 400 Series 34-108, Bolt 1/4-20 (Case to Cover) 500 Series ‘90-110 Bolt 1/4-20 (Brake-Dise) 5300 Series 90-110 Bolt §/16-24 (Shifter Rod) 500 Series 13.5 ‘Bolt 1/4-20 (Case to Cover) ‘600 Series aa08 Bolt 8/16-18 (Axle Support Housing) 600 Series 156-180 : Bolt 1/4-20 (Shift Lever Housing) 600 Series 84-108 Bolt 1/4-20 (Brake-Dise) 600 Series oa) [Bolt 1/4-20 (Case to Cover) 1200 Series Est} Bolt 2/4-20 (Shift Lever Housing) 1200 Series 84-108 Bolt 1/4-20 (Differential) 1200 Series 710 Bolt 1/4-20 (Case to Cover) 1300 Series WoIi0 Bolt 1/420 (Differential) 1300 Series 7.10 ‘Bolt 1/4-20 (Case to Cover) 1400 Series #10 Bolt 1/4-20 (Shift Lever Housing) 1400 Series 284-108 Bolt 1/4-20 (Differential 1400 Series 70. Bolt 1/4-20 (Case to Cover) T700 & 2000 Series #10 Bolt 1/4-20 (Shift Lever Housing) 1700 & 2000 Series 7210 Bolt 5/16-18 (Axle Support Housing) 1700 & 2000 Series 18 Bolt 1/4-20 (Differential) 1700 & 2000 Series 710 [Bolt 1/%-20 (Case to Cover) series FT Bolt 1/4-20 (Shift Lever Housing) 2800 Series 5:10 Bolt 5/16-18 (Axle Support Housing) 2800 Series 16-18 Bolt 174-20 (Differential) 2800 Series 7-10 Bolt 3/8-16 (Axle Support Housing) 2300 Series 20-28 It 174-20 (Case to Cover) 2400 Series B10 Bolt 1/4-20 (Axle Support Housing) 2400 Series B10 Bolt 1/4-20 (Differential) 2400 Series 7210 Bolt 5/26-18 (Case to Cover) 2500 Series i515 Bolt 3/8-16 (Differential) 2500 Series 35-40 Bolt 1/2-13 (Azle Support Housing) 2500 Series 80-85 Serews No. 10-24 (Cover) RAD. BORE Bolts 1/4-20 (Retainer Cap) RAD. 90-110 CAUSE REMEDY UNIT CANNOT BE SHIFTED (OR DIFFICULT To SHIFT) [Gears improperly installed. ‘Review positioning of gearing. [Forks and Rod assembly incorrectly installed. ‘Remove assembly. Recheck and correctly position parts. [Axle Housing not installed or not tightened. ‘Seal retainers are not properly seated. Tighten axle housing bolts [Same items covered under heading, “Axles Cannot be Turned (Same Direction) Review remedy listed. While Unit in Neutral Gear". Determine if finger of shifting lever ig correct Shifting lever improperly positioned, for the unit and correctly installed. Check to rake sute shift lever housing has required gasket. Check to determine if alignment marks are on Shift lever housing misaligned to case, tunitand that they are correctly positioned. Also, determine If bend on shaft ls in correct position. Litho ia U.S.A. 4/73 19lntrodvetion PEERLESS MECHANIC'S HANDBOOK CAUSE, REMEDY, UNIT CANNOT BE SHIFTED (OR DIFFICULT TO SHIFT) (Continued) Parts missing. Install missing parts, Equipment cluteh not disengaging, Adjust cluten according to equipment instructions. Shifter stop assembled backwards. (Check to determine that notch in STOP aligns with shifter forks in NEUTRAL position, ‘Chamfer on shift gears on wrong side. Check to determine that bevels on shifter gears are cor- eet (fork flanges should be toward each other). On 3 gear cluster, small gear and medium gear chaiufers go down toward big gear. UNIT IS NOISY Gearing overly noisy ~ chatter, ete, (Check lubrication is at proper content. ‘Metallic pieces and/or other foreign objects in unit, Check for and remove bits of broken metal, loose wash- ers, ete, ‘Worn gears. ‘Remove and replace with new gears, Worn bearings ~ mainly input shaft ball. . bearing. Replace bearing. UNIT JUMPS OUT OF GEAR Shifting lever improperly assembled in housing. Disassemble shifting lever and determine if properly assembled, Teeth of gears are worn beyond tolerances, Check gears. Replace worn gears. Spring in shifter fork weak or broken, Replace spring. ‘Attaching screws for shift lever and housing assembly not properly torqued. ‘Torque screws to 10 Ibs. tt. Shift lever bent and hitting unit frame, Replace shift leves Shift rod grooves worn, Replace shift rods. A ‘Shift rod of improper length or grooving in- stalled. Check rod length. Replace rod with correct part. Constant mesh gears improperly installed on counter shaft. Reposition gears. AXLES CANNOT BE TURNED (SAME DIRECTION) WITH UNIT IN NEUTRAL GEAR Axle housing not installed (or not tightened), Seal retainers are not properly seated. Tighten axle housing bolts. Burrs on gearing. Remove gear and hone with a stone, Parts missing. Install missing parts, Broken shifter stop allowing unit to be shifted into two speeds at the same time. Replace snap rings on shift rod out of groove. (Continued on next page.)PEERLESS MECHANIC’S HANDBOOK Introdvetion CAUSE ‘REMEDY AXLES CANNOT BE TURNED (SAME DIRECTION) WITH UNIT IN NEUTRAL GEAR (Continued) ‘Thrust washers in wrong position. Recheck thrust washer and reposition, if wrong. ‘Bearings not pressed in deep enough. ‘Use the proper bearing tocl to seat the bearing. Improper fit of ease to cover. Recheck positioning of thrust washers. A misplacement oF omission of washer can cause binding. Dowel pins not installed. Install dowel pins. Gears improperly installed. (Check unit for correct assembly of parts. Tnput shaft not properly installed. Input shaft epline must be fitted into gear and must be ‘tapped completely into the case. Differential installed improperly. Re-check positioning of bolts in differential ~ must be opposite output shaft gear (except 2400). Seal retainers improperly positioned. Determine seals are correctly installed. UNIT DOES NOT DRIVE Differential bevel gears broken. Replace, 3 gear cluster counter shaft key sheared in Replace. ‘Model 600, 350 and 400. ‘Stripped teeth on gears. ‘Replace. ‘Keys sheared in drive pulleys. Replace. ‘Broken input gear. Replace. 1 TESTING ‘The absence of binding and oil leakage are the best indications that the unit has been properly reassem- To ease in turning of the various shafts, in sert a tool (such as a punch or a socket head Serew key) into the keyway, however, do not . force if the shaft is binding. bled. Though other, more elaborate, tests can be done, this would be the perogative of the servicing ‘Reason for unit binding: agency, since the following checks are considered 1. Reused or lack of gasket. adequate, 2. Oil seal retainers installed backward. 3, Mis-installed thrust washers. With the ehift forks in neutral, rotate both 4 axle ends in the same direction. They should turn smoothly although a little effort may be necessary. The brake shaft should rotate Whenever the axles turn together, but in nevtral, the input shaft should not turn, By moving any shifter gear into mesh, a greater drag should be felt on the axles on both the input and brakeshaft should turn. |. Differential installed backward. 5, Mis-assembly of shifting parts. 8. Mis-placement of spacers. TT. Foreign matter blocking) gear teeth ‘mesh 8, Shifter stop installed backwards. 9, Input shaft not completely in case. 10. ‘Mis-alignment of case and cover. Align with dowels before tightening cap Xu ranPEERLESS MECHANIC'S HANDBOOK Transmissions SECTION 2 TRANSMISSIONS SHIET LEVER HOUSING. MOUNTING BRACKET SNAP RING INPUT SHAFT BRAKE SHAFT BRAKE SHAFT (OPTIONAL) SPROCKET Figure 2-1 Transmission Bottom View VEHICLE FRONT ™ = D VERTICAL 1 350 and 400 SERIES TRANSMISSIONS VEHICLE LEFT SIDE VEHICLE RIGHT SIDE Figure 2-2 Shift Pattern Figure 2-3 Removing Brake Shaft Snap Ring, SHIFT LEVER SCREWS (3) Figure 2-4 Transmission Side View Litho in U.S.A. 6/73 CAUTION DECLUTCHING IS REQUIRED WHEN SHIFTING TO ‘AVOID GEAR CLASHING AND DAMAGE. A. GENERAL ‘The Model 350 and 400 series transmission are basically the same. The major difference is that the 350 series has bronze bushings and the 400 series has needle bearings. The trans- mission may havea brake shaft if the application requires a transmission brake. The model number is stamped on the cover. Figure 2-4. B, TRANSMISSION DISASSEMBLY 1, Clean the outside surface of the transmission. Position shift fork in neutral position (Figure 2-2). Remove screws (3) holding shift lever and shift lever housing. Remove shift lever housing. For repair of shift lever assembly, SECTION 10. 2. Ifa brake shaft is on the unit, remove snap ring from shaft. Clean shaft of dirt or burrs. 3, Remove snap ring holding sprocket to the output shaft and remove sprocket. Clean shaft of dirt and burrs. 4, Remove two dowel pins by tapping out with metal punch. Remove cover screws (8). NOTE: Wipe grease from parts as they are removed.Frmnieone PEERLESS MECHANIC'S HANDBOOK COVER, SEAL PROTECTOR 7a70T02 5, Prior to lifting off’ the cover, install seal protector 670182 to protect seal for output shaft on units having it, Remove cover and eect gases seat INPUT SHAFT ‘Figure 2-5 Seal Sleeve #870182 REVERSE IDLER GEAR SPACER SHIFTER FORKS Sane SHIFTER STOP swat bad 6, Rer Adle shaft, and , Remove reverse idler gear, shat, sarin Spacer. nutall gear with bevel cut foward spacer, THRUST WASHER SHIFTER SHAFT| SHIFTING GEARS eee INPUT SHAFT BEVEL GEAR| Figure 2-6 SHIFTER ROD SHIFTER FORK SHIFTER ROD. T. Remove shift fork, gears and shaft assem~ SHIFTER blies. Grasp shifter forks, gears and shaft STOP and raise up while tapping shifter shaft bevel gear with handle of hammer to separate from shaft splines. Ifno service is required, put unit aside for easy reassembly. ‘To repair ‘unit, refer to SECTION 10, sshieteR SHAFT seve, BEVEL GEAR SPLINES SHIFTER GEAR aeveL Figure 2-7 Shifter Mechanism TONG KEWWAY SHORT KeWay ourPur eno LARGE GEAR 8, Remove cluster gearsand shalt. To separate =| gears, remove outer geara first, then slide a) Stf middle gear and key. For replacement, note thatthe larger gear belongs on the short a ‘eyway opposite. the oatpat ent of the hate uw Note the bevel edge position of the gears GEAR * ® BRAKE ENO epium eke on Apliebl st BEVEL bes | Figure 2-8 Cluster Gear and Shaft 22PEERLESS MECHANIC'S HANDBOOK THRUST WASHERS SHIFTER SHAFT BEVEL GEAR THRUST BEARING. Figure 2-9 SNAP RING OIL SEAT METAL CASING INPUT SHAFT Figure 2-10 Removing Input Shaft Oil Seal (400 Series Only) PRESS IN FLUSH WITH CASTING, BEARING. (400 SERIES ONLY) Figure 2-11 THRUST WASHER THRUST BEARING. lL SEAL TAND BEVEL GEAR [B50 SERIES TRANSMISSIONS 400 SERIES TRANSMISSIONS Figure 2-12 Input Shaft (Cutaway View) Transmissions 9, Remove the shifter shaft bevel gear, and the thrust bearing and washers. 10. To remove the input shaft oil seal in the 400, series, use metal screws topuncture the seal casing and lift out seal. Seal must be re- placed, Clean the input shaft of scratches and sharp edges. Remove the snap rings and thrust washer and pressor tap the input shaft into the case, A thrust washer (Model 350) or a thrust washer and a thrust bearing (Model 400) should be on the shaft: C, INSPECTION AND REPAIR. Examine all parts. Check gears for worn or chipped teeth and splines. Check shaft for wear or scratches and condition of snap ring grooves , splines and keyways. Examine case and cover for cracks and stripped thread condition. To replace bearing or bushing, refer toSECTION 11. To replace input shaft bearings, drive out bear- ings using bearing driver 670207. Inside bearing protrudes above the casting. See Figure 2-11 for installation dimensions. D. ASSEMBLY 1. Install and secure the input shaft. Refer to Figure 2-12 for arrangement of parts depend- ing upon series being repaired. 23PEERLESS MECHANIC'S HANDBOOK ‘Teanamisioos ‘BUSHING (50 SERIES) SHIFTER SHAFT THRUST BEARING (400,SERIES) BEVEL GEAR WASHER; SNAP RING? BUSHING (350 SERIES) BEARING (400) SERIES) ‘Figure 2-13 Transmission Sectional View (350 shown) NEUTRAL POSITION. Pigure 2-14 24 2, Install cluster gears and shaft with a thrust ‘washer between the large gear and case. The ‘small and middle gear bevel faces down, the large gear bevel faces up. Install the shifter bevel gear. For 400 series, be sure thrust washers and bearings are be- tween gear and case. Align the gear-with the center of the hole. 4 Install the shift mechanism (Figure 2-7). Try to align the gear and shaft splines before in- serting the shaft. To do so, visualize the shifter mechanism in position and note the position of one spline. " Position a spline on the gear so that its relationship is the same. Carefully guide the shifter shaft through the gear, disturbing the gear and thrust washers 4s liftle as possible. ‘The shifter mechanism ‘must be held firmlyto keep parts fromchang- ing position so that they appear asin Figure 2-13. Install shifter stop. 5, Install reverse idler shaft, gear and spacer. Install gear with bevel out toward spacer. ‘6, Install washers on the cluster geai and shifter shafts. Coat 12 oz. of EP, Lithium grease around gearing if unit uses grease. (See chart SECTION 1, Paragraph E.) 7, Install gasket to case. 4, Install cover to case and secure by cross- tightening eight cap screws to 90-110 in. Ibs. If cover does not close, use needle-nosed pliers to reposition shifter components until cover seats. Do not force cover on. Install oll seals on 400 series. Use oll seal sleeve #670143 andoil seal driver #870203 on the brakeshaft oil seals. Use ofl seal sleeve #670102 and oil seal driver #670209 on the input shaft oil seal. 10. Install new gasket, shift lever and housing ‘with three socket head cap screws. 11, Install sprocket and snap ring on output shaft. 12. ‘Turn input shaft to check for binding. Check for correct shifting pattern. E, TESTING UNITS 1.,With the unit in neutral, turn the output sprocket. The input shaft should not turn. ‘With unit in any gear, input shaft turns,PEERLESS MECHANIC'S HANDBOOK 200 Series SECTION 2-1 TRANSMISSIONS (200 SERIES) MOUNTING open NUMBER Figure 2-15. Model 200 Transmission riven Figure 2-18. Case Removed REVISED 1/89 A. OPERATION NOTE: Numbers in parentheses refer to Figure 2-17. 1. The input shaft (7) idles through the two gears (5) and (6) held in position by the bushing (2) flanges, a shouldered key (12), and thrust washers (18). The input shaft (7} however, turns the shifter lug (9) splined to the shaft by the shouldered key (12). 2. With the lug (8) centered on the key (12), the unit is in neutral, since neither of the 21 tooth nor 25 tooth gears is rotating. 3, If the shifter lever (4) is moved to LOW position, rotating its rod and fork to the eft, the fork engaged in the lug (8) moves leftalong the shaft (7) sothat its lugs engage lugs in the 21 tooth gear (5). There is a reduction in speed through the 25 tooth (6) gear to the axle (8), 4, By rotating the shifter rod and fork (4) (HIGH) so that the lug (9) goes right along the shaft (7) to engage the 25 tooth gear (6), there is aspeed increase through the driven 21 tooth gear (6) to the axle (8). B, REMOVAL 1, When removing the transmission from the equipment loosen the mounting bolts to re- Lieve pressure on the belt or link chain. 2. Clean the outside of the unit, Grind off any high spots on the axle. Clean off any rust, corrosion, or paint which will bind parts during disassembly. 3. Remove any attached parts as pulleys or sprockets. 4, Note the unit identification number on the case. . DISASSEMBLY 1, Remove the capscrews retaining the housing halves together. Lift the case from the cover while pressing on the axle and input shafts to keep those parts remaining with the cover. 2. Clean excess grease from the cover and from around the transmission internal parts. Lift out the axle and gears. Note that the axle extension from the gears is of different Iength. 4, Remove the input shaft, drive lugand gears, and shifter shaft as a unit; then separate parts. LITHO IN U.S.A. 25