Cub Cadet Big Country 2004- Manuals

Poly Bed 4 X 2 Drive System 3 3. DIAGNOSIS: CONFIRMING TRANSAXLE FAULT 3.1. Get as much information as possible from the customer regarding symptoms and circum-stances. 3.1. Inspect the vehicle for physical damage and clues regarding the nature and cause of failure. 3.2. Carefully operate the vehicl...

Poly Bed 4 X 2 Drive System 4 4.5. There is a black plastic cover on the gearshift control. Slide it rearward, then lift it away from the gear shift control to expose the cable attach-ment. See Figure 4.5. NOTE: There is a lip at the front edge of the cover that will provide sufficient purchase to s...

Poly Bed 4 X 2 Drive System 5 4.12. Within the housing for the shifter control there is a torsion spring that returns the shift lever to the center of its travel. There is not a detent mech-anism in the shifter control. See Figure 4.12. 4.13. On installation of the shifter control: • Position the bo...

Poly Bed 4 X 2 Drive System 6 Shift Control Adjustment 4.20. To adjust the shift cable, use the neutral safety switch to confirm the neutral position. See Figure 4.20. • Connect a powered continuity light or an Ohm meter between the terminal on the neutral switch and a good ground. This test works k...

Poly Bed 4 X 2 Drive System 7 Differential Lock Control In normal operation, a differential allows the two rear wheels to rotate at different speeds. In a turning maneuver, the wheels toward the outside of the turn follow a path that describes a greater circumference than the wheels toward the insid...

Poly Bed 4 X 2 Drive System 8 4.34. If the linkage binds, disconnect the cable to iso- late the external portion of the linkage from inter-nal transaxle components. 4.35. Disconnect the differential lock control cable from the differential lock control lever: Pull the cable forward to get clearance ...

Poly Bed 4 X 2 Drive System 9 4.40. Tighten the cable bracket mounting bolts to a torque of 78 in-lb. (8.8 N-m) on installation. 4.41. The cable is secured to a bracket near the front mounting point of the engine and transaxle cra-dle. See Figure 4.41. 4.42. The cable is secured by two jam nuts that...

Poly Bed 4 X 2 Drive System 10 4.48. With the bracket removed, the fuel tank can be moved far enough back to allow the clevis pin to be removed. See Figure 4.48. 4.49. Apply anti-seize compound or white lithium grease to the portion of the pin that the differen-tial lock control lever pivots on when...

Poly Bed 4 X 2 Drive System 11 5. DIAGNOSIS AND SERVICE: DRIVE BELT AND CLUTCHES (CVT OR CONTINUOUSLY VARIABLE TRANSMISSION) 5.1. Performance problems such as lack of power or failure to reach full speed may be caused by: engine performance issues, dragging brakes, or belt/clutch issues. 5.2. Confir...

Poly Bed 4 X 2 Drive System 12 Inspection 5.3. Park the vehicle on a firm level surface, with the ignition turned off, and lift the load bed to provide access to the drive system. 5.4. Allow the exhaust system to cool before pro-ceeding. 5.5. Inspect the CVT system air filter. The filter is located ...

Poly Bed 4 X 2 Drive System 13 5.12. Loosen the hose clamp that secures the molded hose from the air filter to the plenum. See Figure 5.12. 5.13. Remove the two bolts that hold the air filter housing to the air filter bracket using a 1/2” wrench, and remove the filter assembly. 5.14. The exhaust pip...

Poly Bed 4 X 2 Drive System 14 5.19. Inspect the belt and clutches (pulleys) for obvi- ous damage and wear: See Figure 5.19. • The belt should measure at least.827” (21 mm) across the outside (wide) surface (service limit). If it measures less than this it is worn, and should be replaced. • New belt...

Poly Bed 4 X 2 Drive System 15 5.25. Confirm that the throttle cable, and the travel stops on the throttle cable are adjusted to pro-vide the full range of travel without straining the cable: 5.26. There should be roughly 3/16” (4.8 mm) of play at the eyelet that connects the throttle cable to the t...

Poly Bed 4 X 2 Drive System 16 5.29. Hold the throttle arm against the stop screw. Adjust the stop screw to set the engine speed to 1,100 RPM + 50. 5.30. Release the throttle arm, then set the governed idle speed to 1,200 RPM + 50. See Figure 5.30. 5.31. The idle speed is controlled by the phillips ...

Poly Bed 4 X 2 Drive System 17 5.35. As the driving pulley compresses the belt, it is forced outward in the tapered sheave. NOTE: As the effective diameter of the driving pulley increases, the belt is drawn deeper into the sheave of the spring loaded driven pulley, reducing its effective diameter. T...

Poly Bed 4 X 2 Drive System 18 5.44. If it is necessary to hold the crankshaft from turn- ing: choose one of three methods. See Figure 5.44. • Remove the spark plug using a 13/16” (21 mm) wrench. With the piston rising on the compres-sion stroke pack the cylinder with starter rope to act as a piston...

Poly Bed 4 X 2 Drive System 19 5.50. After the belt is removed, the driven pulley can be removed: See Figure 5.50. • Take the bolt and washer that secure the pulley onto the transaxle input shaft completely off using a 12 mm wrench. • Slide the pulley off of the input shaft. It may be necessary to c...

Poly Bed 4 X 2 Drive System 20 5.57. Beyond the warranty period, if a dealer chooses to service a driven clutch, service information and specialized tools are available from: Hoffco/Comet Industries 358 NW F Street Richmond, IN 47374 5.58. The CVT housing connects the engine to the transaxle. It can...

Poly Bed 4 X 2 Drive System 21 6.6. Lift the bed. Remove the exhaust pipe and the CVT assembly, including the housing, as described in the CVT section of this manual. See Figure 6.6. 6.7. Index the forward-neutral-reverse shift arm on the transaxle to the splined shaft that it mounts to. Remove the ...

Poly Bed 4 X 2 Drive System 22 6.13. Remove and discard the cotter pins securing the clevis pins into each brake cable clevis/actuator arm connection. Remove the clevis pins. See Figure 6.13. 6.14. Disconnect the red wire with white trace from the neutral switch, located on the rear surface of the u...

Poly Bed 4 X 2 Drive System 23 6.19. Jackstands must be placed under the frame, not the engine/transaxle cradle. See Figure 6.19. NOTE: The cross member that the bracket for the dog-bone joint is attached to provides a con-venient place for jackstands. It is near the center of gravity: the entire ve...

Poly Bed 4 X 2 Drive System 24 7. TRANSAXLE INSTALLATION NOTES: 7.1. Reverse the removal procedure to install the transaxle. The following items are tips, remind-ers, and torque specifications. 7.2. When mounting the transaxle to the cradle: • Roll the transaxle into position. • Attach it loosely to...

Poly Bed 4 X 2 Drive System 25 NOTE: 1 May be inaccessible with torque wrench. NOTE: 2 If locking feature on nut is worn, replace the nut or apply releasable thread-locking com-pound such as Loctite 242 (blue). NOTE: 3 Left-hand threads Table 1: Drive System Torque Values Item Torque Note cradle to ...

Poly Bed 4 X 2 Drive System 26 8.6. Remove the nut and bolt (top) that connect the link assembly to the frame using a pair of 15/16” wrenches. See Figure 8.6. 8.7. Remove the nut and bolt (bottom) that connect the link assembly to the engine and transaxle cradle using a pair of 19mm wrenches. 8.8. W...

Poly Bed 4 X 2 Drive System 27 9.5. After the wheels and brake drums are removed from the axle shafts, remove the brake shoes as described in the “Brakes” section of this manual. See Figure 9.5. 9.6. Remove the Brake backing plate assembly from the transaxle using a 17 mm wrench. See Figure 9.6. NOT...

Poly Bed 4 X 2 Drive System 28 9.9. When placed on the bench, take note of the ori-entation of the transaxle components. Match marks will ease the assembly process but the following relationships are correct: • The brake backing plates attach with the lever and cam to the rear of the transaxle. • Th...

Poly Bed 4 X 2 Drive System 30 9.20. Remove the seal from the axle tube. See Figure 9.20. NOTE: The oil seal seats against a shoulder in the tube. Hook the seal removal tool under the lip of the seal to avoid scratching the bore that the seal fits in. 9.21. Technical Info. for the Curious : See Figu...

Poly Bed 4 X 2 Drive System 31 Transaxle housing and internals: 9.26. Prepare to separate the case: Clean any rust or burrs from the input shaft with emery cloth, and remove the spacer if it was not taken off previ-ously. See Figure 9.26. 9.27. Position the case so that it rests securely with the in...

Poly Bed 4 X 2 Drive System 32 9.31. Clean the left half of the housing, and inspect the three bearings that reside in it. See Figure 9.31. • The largest bearing supports the differential. It may be driven out of the housing from the out-side-in. • The nose of the input shaft rides in a sealed beari...

Poly Bed 4 X 2 Drive System 33 9.35. Lift the 51-tooth sprocket off of the reduction shaft along with the 19-tooth sprocket from the input shaft and the link-belt reverse chain. See Figure 9.35. 9.36. Remove the washers that are behind the sprock- ets on the input shaft and reduction shaft. See Figu...

Poly Bed 4 X 2 Drive System 34 9.40. Use a magnet to remove the pin that retains the shift lever. See Figure 9.40. 9.41. After the pin is removed, slide the shift arm into its bore to retract the pin from the groove in the shift collar. 9.42. When the pin is clear of the groove, lift the shift colla...

Poly Bed 4 X 2 Drive System 35 9.46. Like the input shaft, it will be necessary to clean any rust from the exterior part of the shift lever before it is removed. See Figure 9.46. 9.47. The shift lever can be removed through the inside of the housing. there is a roller on the pin that engages the shi...

Poly Bed 4 X 2 Drive System 38 Table 2: Transaxle Torque Note 1: Apply releasable thread-locking compound such as Loctite 242. Note 2: The cable attachment arm should be 90 degrees rearward from the shift arm within the tran-saxle. Note 3: Confirm proper return action from he torsion spring. Item To...

Poly Bed 4 X 2 Brake System 39 ABOUT THIS SECTION: This section covers brake service and adjustments on the “poly bed” Utility Vehicle 4 X 2 Model 414 (37AN414J710). 1. MAINTNANCE AND DESCRIPTION OF THE BRAKE SYSTEM: 1.1. It is important that the brakes on the Big Country vehicle be properly maintai...

Poly Bed 4 X 2 Brake System 40 1.5. Any significant wear, damage, or binding should be addressed prior to making an operational test. NOTE: the operational test should be performed in a safe location that is free of traffic, obstacles, and hazards. 1.6. If the operator has any specific brake perfor-...

Poly Bed 4 X 2 Brake System 41 • Lift and safely support the back of the Big Coun-try vehicle. • Remove the rear lug nuts using a 19 mm socket, and lift off the rear wheels. • Release the parking brake, if applied. 2.4. Verify the correct orientation of the brake arm on the brake actuator cam: The c...

Poly Bed 4 X 2 Brake System 42 2.12. To remove the brake shoes: pivot the shoes away from the backing plate. This will reduce the spring tension. 2.13. Using either a screwdriver or a brake adjusting spoon, step the shoes over the end of the cam. See Figure 2.13. 2.14. Inspect the bearings, seals, s...

Poly Bed 4 X 2 Brake System 43 2.18. Confirm that the shoes and springs are properly seated. See Figure 2.18. 2.19. Inspect the brake drums: See Figure 2.19. • The studs should not exhibit any damage. • The splines should be in good condition. • The friction surface should be clean. • The friction s...

Poly Bed 4 X 2 Brake System 44 3.2. Adjust the nut and jam nut on the bolt that joins the clevis (pinned to the brake pedal arm) to the pivot pin that goes through the equalizer bracket. See Figure 3.2. 3.3. Place a bathroom scale between your foot and the brake pedal. Depress the brake pedal and se...

Poly Bed 4 X 2 Brake System 45 3.11. Confirm that the parking brake light illuminates on the instrument panel when the parking brake is applied, and goes out when the parking brake is released. See Figure 3.11. 3.12. If necessary the parking brake switch can be adjusted in its slotted mounting brack...

4 X 2 Drive System - (Steel Bed) 47 ABOUT THIS SECTION: This section covers the drive system and transaxle used in the Big Country utility vehicle model series 420 and 430. There was also a low-volume series 410 that used the same transaxle without the differential lock feature. The information in t...

4 X 2 Drive System - (Steel Bed) 48 2.10. A blocked vent can provoke oil leaks. The vent is located at the top of the transaxle housing. See Figure 2.10. 2.11. To change the gear lube : Clean the area around the fill and drain plugs before removing either. 2.12. Place a drain pan under the transaxle...

4 X 2 Drive System - (Steel Bed) 49 3.6. An extremely bad axle bearing can mimic a dragging brake. If the axle shaft does not run concentric to the axle tube that the brake is mounted to, the brake drum will rub on the shoes when the brakes are fully released. This will pro-duce sluggish vehicle res...

4 X 2 Drive System - (Steel Bed) 50 4.6. Start the engine and check idle speed. The engine should idle at 1,400 RPM + 150. Correct the idle speed if it is not in this range. If it is higher, the clutch will drag. 4.7. The idle speed is controlled by the amount of tension on the small spring on the g...

4 X 2 Drive System - (Steel Bed) 51 4.13. At around 1,400 RPM the sheaves of the driving pulley should begin to close on the belt. See Figure 4.13. 4.14. There should be no significant power transmitted through the belt at idle speed. See Figure 4.14. Figure 4.13 Idle speed: driving pulleysheaves ar...

4 X 2 Drive System - (Steel Bed) 53 5.5. Key points to inspect on the driven pulley are the ramp surfaces on the cams, and the polymer buttons that ride against the ramps. See Figure 5.5. • A worn ramp surface on the cam will change the acceleration and power characteristics of the drive system. • A...

4 X 2 Drive System - (Steel Bed) 54 6.4. Remove the drive belt. 6.5. After the center bolt is loosened, remove the three screws that hold the cover onto the driving pulley. 6.6. Slide the cover off of the driving pulley. There is not enough clearance to remove the driving pul-ley with the cover in p...

4 X 2 Drive System - (Steel Bed) 55 7. TRANSAXLE REMOVAL AND REPLACE-MENT The transaxle is carried on the engine/transaxle cradle, and the entire cradle moves up and down with the travel of the suspension. It pivots on a dog-bone joint to allow for some degree of axial twist in relation to the rest ...

4 X 2 Drive System - (Steel Bed) 57 7.21. Lift up on the bracket to remove it from the tran- saxle, complete with the actuator and the vac-uum reservoir (the black sphere mounted to the top of the bracket). It is not necessary to discon-nect the vacuum lines from the reservoir or the actuator. 7.22....

4 X 2 Drive System - (Steel Bed) 58 7.29. Remove the bolt that connects the front of the transaxle housing to the torque bracket on the engine/transaxle cradle using a 3/8” wrench and at 7/16” wrench. See Figure 7.29. 7.30. Loosen the mounting bolts that connect the tran- saxle to the mounting ears ...

4 X 2 Drive System - (Steel Bed) 59 8. TRANSAXLE INSTALLATION NOTES: 8.1. Reverse the removal procedure to install the transaxle. The following items are tips, remind-ers, and torque specifications. 8.2. When mounting the transaxle to the cradle, attach it loosely to the cradle using the four bolts ...

4 X 2 Drive System - (Steel Bed) 63 11.4. Remove the detent set screw using a straight- blade screwdriver. Retrieve the detent ball and spring from the detent screw bore using a mag-net. See Figure 11.4. 11.5. Position the housing differential lock side-up on 4x4 dimensional lumber, or a similar sup...

4 X 2 Drive System - (Steel Bed) 70 13.13. If it is necessary to remove the bearing, use a bearing puller. See Figure 13.13. 14. TRANSAXLE: AXLE TUBES 14.1. If brake drum has not already been removed from the axle tube, perform the following steps: 14.2. Remove the brake drum. See Figure 14.2. NOTE:...

4 X 2 Drive System - (Steel Bed) 71 14.4. Remove the brake shoes: • Release the small blue tension spring adjacent to the brake adjuster. • Remove the brake adjuster • Pry the tail of each torsion spring over the lip that it seats behind on the cast brake bracket. • Lift away the shoes and springs. ...

4 X 2 Drive System - (Steel Bed) 72 14.10. Drill a small (1/8” or less) pilot hole into the out- side edge of the retaining ring. Drill most of the way through the ring, but do not drill into the axle shaft. Enlarge the hole with a 1/4” bit. See Figure 14.10. 14.11. Split the ring with a cold chisel...

4 X 2 Drive System - (Steel Bed) 75 15.6. Remove the three screws securing the grid screen to the grid screen holder using a 10 mm wrench. Remove the grid screen. See Figure 15.6. 15.7. Remove the two screws that hold the top of the fan cover to the engine using a 10 mm wrench. Install one or two of...

4 X 2 Drive System - (Steel Bed) 76 15.11. The fuel pump can be tested on the bench using a hand operated vacuum pump to confirm the initial tests. See Figure 15.11. 15.12. With the vent blocked, the diaphragm should be able to hold vacuum generated by the hand pump. See Figure 15.12. NOTE: Recommen...

4 X 2 Drive System - (Steel Bed) 77 15.18. Rotate the engine crankshaft manually to locate top dead center (TDC) on the compression stroke for cylinder #1 (front cylinder). See Figure 15.18. • Rotating the crankshaft clockwise (seen from the fan side of the engine) will produce a puff of air from th...