Cub Cadet 6 x 4 Big Country- User Manual

Section 1: Introduction 1 - 1 1 1. Safety 1.1. Before servicing the Big Country, technicians should be familiar with the vehicle and the Oper-ator’s Manual that applies to it. There are impor-tant instructions that pertain to safe and correct operation and service of the Big Country con-tained in th...

Section 1: Introduction 1 - 2 2.8. The engine family and specification numbers are located on a tag on the rear cylinder shroud of the engine. 2.9. The transmission identification number is located on a flat surface adjacent to the dipstick. See Figure 2.9. 3. Fasteners 3.1. A combination of metric ...

Section 1: Introduction 1 - 3 1 4.3. Universal Joint Spacer Tool : See Figure 4.3. 4.4. Part Number 703-05104 is used to set the cor-rect clearance between the end of the axle assembly and the end of the universal joint on the drive axles. See Figure 4.4. Figure 4.3 Universal Joint Spacer Tool Part ...

Section 1: Introduction 1 - 4 6. Lubrication Specifications. Application Type Amount Part Number Engine Oilgeneral use 10W-30 API: SJ 1.16 qt. 1.48 qt. with / filter 737-3030A Engine Oilsub-freezing 5W-30 API: SJ 1.16 qt.1.48 qt. with / filter Obtain Locally Gear Lube Drive System Fluid Plus 189 oz....

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 2 2.8. Inspect the shift interlock mechanism. If the interlock mechanism does not work properly, refer to the “Shift Interlock and Clutch Pulley Brake Adjustment” section of this manual. See Figure 2.8. 2.9. Remove the hairpin clip and flat washe...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 4 NOTE: When the brake is released and a gear is engaged, the pin that connects the clevis to the transmission shift lever should be centered in a slot in the interlock arm. If it is not, refer to the “Shift Interlock and Clutch Brake Adjustment”...

Section 2: Clutch, Transmission, Brakes, Linkages 2- 5 2 5.4. Pivot the cable in the differential lock arm so that the cable aligns with the slot in the arm. This will allow the barrel at the end of the cable to be remove from the arm. See Figure 5.4. 5.5. Trace the cable forward to the bracket on t...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 6 5.13. Withdraw the pivot pin far enough to clear the differential lock lever, and remove the lever. See Figure 5.13. 5.14. Reverse the removal procedure to install the differential lock lever. 5.15. Use the following procedure to install the di...

Section 2: Clutch, Transmission, Brakes, Linkages 2- 7 2 6.3. When the differential lock lever is released, there should be slight slack in the cable. 6.4. When fully engaged, the differential lock arm should move up at least 3/4” as measured along the cable. See Figure 6.4. NOTE: The differential l...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 8 8.5. Remove the jam nut from the end of the brake cable core using a deep ½” socket on an exten-sion. See Figure 8.5. NOTE: Use a pair of slip joint pliers to hold the cable, if necessary. 8.6. Loosen the large jam nuts that secure the cable ho...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 10 8.25. Working at the front of the Big Country, thread the first jam nut all the way up the cable housing end until it stops against the shoulder. See Figure 8.25. 8.26. Slip the cable core through the slot in the bracket, and draw the end of t...

Section 2: Clutch, Transmission, Brakes, Linkages 2- 13 2 10.7. Loosen the jam nuts that hold the clutch pulley brake and shift interlock cable to the bracket using a pair of 1/2” wrenches. NOTE: A crowfoot socket may be helpful. 10.8. Slip the cable out of the bracket, and pull the yoke on the end ...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 18 13.9. On the bench, remove the nut from the shoulder bolt that the clutch pulley brake arm pivots on using a 9/16” wrench and a ¾” wrench. See Figure 13.9. 13.10. Pull the brake arm off of the interlock bracket, and unhook the spring that conn...

Section 2: Clutch, Transmission, Brakes, Linkages 2- 19 2 14. Belt Removal and Replacement 14.1. The Belt should be checked for wear every 40 hours. This is a visual inspection, and does not necessarily involve belt removal. NOTE: The belt is the primary wear item in the drive system. If drive syste...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 20 15. Driven Clutch Pulley Removal and Replace-ment 15.1. Set the parking brake 15.2. Place the shift lever in forward gear. 15.3. Loosen the bolt that secures the driven clutch pulley to the input shaft of the transmission using a 17 mm wrench....

Section 2: Clutch, Transmission, Brakes, Linkages 2- 21 2 16.6. Slip the clutch off the end of the crankshaft. See Figure 16.6. NOTE: It will be necessary to partially remove the key that rides between the clutch and the crankshaft as the clutch is removed. 16.7. To install the driving clutch pulley...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 24 17.30. Remove the air filter assembly. 17.31. Loosen the clamp bolts that hold the right univer- sal joint onto the right out-put shaft of the trans-mission using two 9/16” wrenches. See Figure 17.31. 17.32. If equipped with fixed chain guides...

Section 2: Clutch, Transmission, Brakes, Linkages 2 - 34 19. Torque Table: Clutch, Transmission, Brakes, Linkages NOTES Location Inch-Lbs Foot-lbs Driven Clutch Pulley 420-480 ft-lbs 35-40 ft-lbs Driving Clutch Pulley 240-360 in-lbs 20-30 ft-lbs Transmission-Mounting Bolts 125-147 ft-lbs Universal J...

Section 3: Drive Axle Service 3 - 1 3 1. Lifting the Big Country and Removing the Drive Axle Wheels 1.1. Park the Big Country on firm, level ground. 1.2. Raise the bed if service is to be performed in the engine compartment. 1.3. Turn the key to the off position, and remove it from the key switch. 1...

Section 3: Drive Axle Service 3 - 2 1.12. To install the wheel , lift it onto the hub. It will rest on the center boss of the mounting flange. The valve stem must face out. 1.13. Rotate the wheel to align the holes in the wheel with the holes in the mounting flange. 1.14. Insert one lug bolt through...

Section 3: Drive Axle Service 3 - 3 3 NOTE: There are index marks on each chain tensioner that may be used to check the amount of available travel. See Figure 3.5. 3.6. Check for a mis-aligned axle assembly , per- form the following steps: 3.7. Lift and support the vehicle, according to the directio...

Section 3: Drive Axle Service 3 - 4 4. Chain Tension Adjustment (Early units Equipped With Fixed Chain Guides) NOTE: Chains are used to transfer power from each of the front drive axles to the rear drive axles. The chains are set tight from the factory, and will not reach normal operating length and...

Section 3: Drive Axle Service 3 - 5 3 4.9. If the travel of the chain guide is not sufficient to reach the specified chain tension, the half-link adjacent to the master link can be removed to shorten the chain. See Figure 4.9. 4.10. Repeat the inspection and adjustment on the opposite side of the Bi...

Section 3: Drive Axle Service 3 - 6 6. Chain Removal and Replacement (Early Units Equipped With Fixed Chain Guides) 6.1. Lift and support the Big Country as described in the “Lifting the Big Country and Removing the Drive Axle Wheels” section of this manual. NOTE: It is not necessary to remove the w...

Section 3: Drive Axle Service 3 - 8 7.4. Push the upper tensioner roller down to relieve tension from the chain and lock it in position using a 1/4” steel dowel pin. See Figure 7.4. NOTE: Both tensioners can be locked in this fashion for chain removal. 7.5. If working on the right side of the Big Co...

Section 3: Drive Axle Service 3 - 10 7.15. Disconnect the master link of the chain using a pair of needle-nose pliers. See Figure 7.15. NOTE: If the chain is to be removed, it can be pulled-out at this point. 7.16. Remove the locking pin, and slowly release the lower chain tensioner. 7.17. Loosen th...

Section 3: Drive Axle Service 3 - 11 3 7.34. Push the upper tensioner arm down until the locking hole in the arm aligns with the locking hole in the frame, and insert the 1/4” steel lock-ing pin to hold it in place. See Figure 7.34. 7.35. Install the chain as described in the “Chain Removal and Repl...

Section 3: Drive Axle Service 3 - 12 8.5. Lift the prop rod to allow the “T” slot in the prop rod to clear the pin on the bracket. See Figure 8.5. 8.6. Angle the bracket up at the back to allow the stop tab on the prop rod to clear the bracket as the bed is lifted. See Figure 8.6. 8.7. Tilt the bed ...

Section 3: Drive Axle Service 3 - 13 3 8.15. Pull out and down on the lever to compress the spring. While the spring is compressed, remove the bolt, washer, and spacers by pushing the bolt out with a dowel pin. See Figure 8.15. 8.16. Slowly release the tool, allowing the spring to extend gently. NOT...

Section 3: Drive Axle Service 3 - 15 3 9.18. Release the bale clips that hold the cover on the air filter, and pull the cover off. 9.19. Remove pinch bolts that hold the air filter assembly to the air intake shoulder using a 13mm wrench. 9.20. Remove the two nuts, washers and bolts that the axle ass...

Section 3: Drive Axle Service 3 - 16 10. Front Drive Sprocket Removal and Replacement 10.1. Remove the front drive axle as described in “Front Drive Axle Removal and Replacement” . 10.2. Remove the six bolts and lock washers that hold the sprocket to the drive flange on the universal joint. See Figu...

Section 3: Drive Axle Service 3 - 17 3 11. Universal Joint Removal and Replacement 11.1. Remove the front drive axle as described in the “Front Drive Axle Removal and Replacement” section. 11.2. Remove the front drive sprocket as described in the “Front Drive Sprocket Removal and Replace-ment” secti...

Section 3: Drive Axle Service 3 - 18 11.17. Slide the universal joint outward, until it pinches the tool in position. See Figure 11.17. 11.18. Tighten the nuts on the universal joint pinch bolts to a torque of 48-58 ft-lbs. 11.19. Remove the universal joint spacer tool. 11.20. Reverse the remainder ...

Section 3: Drive Axle Service 3 - 19 3 12.7. Drive the end yoke in the opposite direction, forcing the second cup partially out of the bore in the yoke. See Figure 12.7. 12.8. Remove the second cup. 12.9. Carefully slip the cross out of the end yoke. See Figure 12.9. 12.10. Remove the remaining cup ...

Section 3: Drive Axle Service 3 - 21 3 12.26. Press a new cup partially into one bore of the end yoke. See Figure 12.26. 12.27. Seat the accessible end of the cross in the oppo- site cup. 12.28. Use the universal joint press to push the two cups together, driving the second cup deep into but not com...

Section 3: Drive Axle Service 3 - 22 12.33. Repeat the process on the second side of the universal joint. See Figure 12.33. NOTE: If any joint fails to move easily, undue loads will be placed on the transmission. NOTES 13. Rear Drive Axle Removal and Replacement 13.1. Lift and support the Big Countr...

Section 3: Drive Axle Service 3 - 23 3 13.6. Examine the rubber travel stops while the axle assembly is out. They can be replaced without removing the axle assembly, but they are much easier to reach with the axle removed. 13.7. To install the rear drive axle assembly, per- form the following steps....

Section 3: Drive Axle Service 3 - 24 15.4. After the first bearing is driven out, a 15/16” socket may be used in conjunction with the soft drift to drive the second bearing (inner bearing) out. 15.5. Lubricate the metal inner bushings and the sleeve bearings with Benaline 920 grease. 15.6. Drive the...

Section 3: Drive Axle Service 3 - 25 3 16. Axle and Bearing Removal and Replacement 16.1. Remove the axle assembly as described in the “Drive Axle Service: Front Drive Axle Removal and Replacement” or “Rear Suspension Service: Rear Drive Axle Removal and Replacement” section of this manual. 16.2. If...

Section 3: Drive Axle Service 3 - 26 16.9. Clean any paint or corrosion from the machined recesses that the axle bearings fit into. 16.10. To put the drive axle assembly together, press the outer axle bearing (larger internal diameter) onto the axle shaft. See Figure 16.10. NOTE: The press should be...

Section 4: Engine and Transmission Support Assembly 4 - 1 4 1. Engine and Transmission Support Assembly: Removal and Replacement as a Unit NOTE: The engine and transmission can be removed individually. This procedure is for the removal of the engine support as an assembly. 1.1. Disconnect the prop r...

Section 4: Engine and Transmission Support Asssembly 4 - 2 1.7. Cover the carburetor to prevent foreign objects from entering the engine. 1.8. Unbolt the air filter bracket from the air intake shoulder using a 13mm wrench, and remove the filter. See Figure 1.8. 1.9. Remove the three bolts that hold ...

Section 4: Engine and Transmission Support Assembly 4 - 3 4 1.21. Disconnect the bullet terminal on the red with black tracer 14 AWG harness wire from the black wire with red trace that leads to the engine ignition. See Figure 1.21. 1.22. Disconnect and plug the fuel line where it meets the second f...

Section 4: Engine and Transmission Support Asssembly 4 - 8 1.72. Remove the nuts and bolts that fasten the front of the engine and transmission support bracket to the isolator mounts using a pair of 9/16” wrenches. See Figure 1.72. NOTE: The ends of each cross-member are open, to provide wrench acce...

Section 4: Engine and Transmission Support Assembly 4 - 9 4 NOTE: The engine support isolators can be unbolted from the frame and removed using a ½” wrench. The bolts attach to threaded inserts in the frame, and there is no nut to reach on the bottom of the frame. See Figure 1.80. 1.81. The engine i...

Section 4: Engine and Transmission Support Asssembly 4 - 10 2.2. Remove the nut, bolt and washer that hold the upper transmission support to the transmission using two 9/16” wrenches. 2.3. Remove the upper transmission support. See Figure 2.3. 2.4. Place a catch pan under the back of the engine and ...

Section 4: Engine and Transmission Support Assembly 4 - 11 4 2.10. Push the engine forward and rotate it to loosen the belt. See Figure 2.10. NOTE: Do not damage the oil drain valve on the front of the sump: it extends below the engine support assembly. 2.11. Roll the belt off the inside edge of the...

Section 4: Engine and Transmission Support Asssembly 4 - 12 3. Engine Support Assembly Isolator Mounts (Rear), Removal and Replacement 3.1. Position the Big Country on a firm level surface in a location that leaves room to work around the rear of the vehicle. 3.2. Turn the engine off, remove the key...

Section 4: Engine and Transmission Support Assembly 4 - 13 4 4. Engine Support Assembly Isolator Mounts (Front), Removal and Replacement 4.1. Position the Big Country on a firm level surface in a location that leaves room to work around both sides of the vehicle. 4.2. Lift and support the bed. 4.3. ...

Section 5: The Fuel System 5 - 1 5 1. Precautions 1.1. Clean, fresh gasoline with a pump octane rating of 86 or higher is to be used. 1.2. Do not fill the fuel tank beyond the mold-parting seam. 1.3. Use common sense when dealing with gasoline: it is flammable and toxic. Common sense pre-cautions in...

Section 5: The Fuel System 5 - 2 2.4. Any of these items can be removed by discon-necting any hoses or wires that are attached to them and gently pulling or prying them out of the fuel tank. 2.5. Each of these items fits through a grommet in the top of the tank. Install the grommet first, then the d...

Section 5: The Fuel System 5 - 3 5 3. Fuel Tank Removal and Replacement 3.1. Park the Big Country on a firm, level surface. Set the Parking Brake, and remove the key from the key switch. 3.2. Drain the fuel tank into an approved container. NOTE: The fuel pump may be used to empty the fuel tank by di...

Section 5: The Fuel System 5 - 4 3.17. Unhook the spring on the end of the differential lock cable from the differential lock lever. 3.18. Remove the differential lock lever. NOTE: The gearshift lever may be left con- nected to the shift rod. 3.19. Remove the front engine and transmission assembly i...

Section 5: The Fuel System 5 - 5 5 NOTE: It is not necessary to remove the filler cap from the filler neck. 3.25. To install the fuel tank, reverse the removal procedure. NOTES 4. Fuel Pump Performance 4.1. When the key switch is turned to the “ON” posi-tion, the fuel pump will normally make a clatt...

Section 5: The Fuel System 5 - 6 4.5. If the pump makes no noise at all, confirm that an electrical problem is not to blame. If the fuel pump has good power supply and good ground, yet fails to operate, it is bad. 4.6. If the pump runs normally, but fails to supply fuel to the carburetor, check the ...

Section 5: The Fuel System 5 - 7 5 NOTE: There is an “IN’ fitting and an “OUT” fit- ting on the pump. They are clearly marked. 5.10. To install a fuel pump, reverse the removal procedure. NOTE: A small quantity of grease or adhesive can be used to help hold the isolator mounts in position while the ...

Section 5: The Fuel System 5 - 8 6.12. Loosen the hose clamp that holds the hose from the air filter to the carburetor using a 5/16” driver or screwdriver. See Figure 6.12. 6.13. Remove the two screws that hold the air intake shoulder to the fan cover using an 8mm driver. 6.14. Loosen the nut and bo...

Section 5: The Fuel System 5 - 9 5 7.11. To install the choke cable, cut the fish tape off of the old choke cable, and attach it to the new choke cable in such a way that it will not snag as it is pulled back through the frame. 7.12. Use the fish tape method to route the new cable back through the p...

Section 5: The Fuel System 5 - 10 8.6. Pull the choke knob out, and verify that the choke arm is pulled tight against the choke arm stop screw. Check that this corresponds with the choke plate closing. See Figure 8.6. NOTE: If the choke arm stop screw needs adjustment, refer to the Honda Engine Serv...

Section 5: The Fuel System 5 - 12 9.30. Adjust the clamps as necessary to make the travel of the pedal coincide with the travel of the throttle input arm. 9.31. If there is insufficient travel in the pedal to attain full travel at the throttle input arm, adjust the pedal stop bolts using two 9/16” w...

Section 6: Front Suspension 6 - 1 6 1. Lifting the Big Country and Removing the Front Wheels 1.1. Turn the ignition off, and remove the keys from the key switch. 1.2. Set the parking brake. 1.3. Chock the rear wheels. 1.4. Remove the wheel bearing dust cover. 1.5. Loosen the wheel bolt using a 3/4” ...

Section 6: Front Suspension 6 - 2 1.8. Remove the front wheel bolt and two flat wash-ers completely. See Figure 1.8. 1.9. Slide the wheel off of the front axle. 1.10. To install a front wheel, apply anti-sieze com- pound to the stub axle to prevent corrosion. See Figure 1.10. NOTE: The stub axle sho...

Section 6: Front Suspension 6 - 3 6 2.7. Pronounced tread wear at the inner edge of either front tire indicates a negative camber con-dition (leaning in at the top) at that wheel. NOTE: If the Big Country is consistently oper- ated with a heavy load, this may be normal wear for the conditions. NOTE:...

Section 6: Front Suspension 6 - 4 2.14. With a helper holding the steering wheel, attempt to pivot each tire around its steering axis. If more than 1/8” of play is present, identify the source of the play. NOTE: Sources of play in this direction are: worn or loose steering rack, worn wheel bear-ings...

Section 6: Front Suspension 6 - 5 6 2.22. Indications: • If a wheel bearing is worn or damaged, refer to the “Wheel Bearing Removal and Replacement section of this manual. • If components of the joint between the axle assembly and the steering knuckle are worn or damaged, refer to the “Steering Knuc...

Section 6: Front Suspension 6 - 6 3.5. With the steering rack centered, the steering wheel spokes should be visually centered. If they are not, this must be dealt with when setting the toe angle. 3.6. Tie a 10’ length of string to each side of the front bumper or brush guard, at roughly the same hei...

Section 6: Front Suspension 6 - 7 6 NOTE: A condition in which the front measure- ment is less than the rear measurement would indicate toe-in . NOTE: A condition in which the front measure- ment is greater than the rear measurement would indicate toe-out . 3.11. Make a table to keep track of adjust...

Section 6: Front Suspension 6 - 8 4. Steering Wheel Removal and Replacement 4.1. Pry the center cover off of the steering wheel. See Figure 4.1. NOTE: There is a lock tab on the back of each of the three spokes. 4.2. Remove the center nut from the steering wheel using a 15/16” socket on a breaker ba...

Section 6: Front Suspension 6 - 9 6 5.6. Drive or press the new bearing into the wheel, applying force to the outer race of the bearing. See Figure 5.6. 5.7. Turn the wheel over. 5.8. Position the spacer and the second bearing in the wheel bore. 5.9. Drive or press the second bearing into the wheel,...

Section 6: Front Suspension 6 - 10 6.7. Remove the nut from the tie rod end, and remove the tie rod end from the steering knuckle. See Figure 6.7. 6.8. Hold the tie rod using a 12mm wrench on the flats that are ground into the rod, and wind the tie rod end off of the tie rod. 6.9. While the tie rod ...

Section 6: Front Suspension 6 - 11 6 7.3. Using two 17mm wrenches, remove the nut from the upper bolt that holds the shock and spring unit to the frame. 7.4. Remove the bolt that holds the bottom of the shock and spring unit to the axle assembly. See Figure 7.4. NOTE: The spring and shock unit is no...

Section 6: Front Suspension 6 - 13 6 8.11. Drive the bushings out of the axle assembly using a hammer and drift. See Figure 8.11. 8.12. Inspect the spacer, bolt, axle assembly, and steering knuckle. See Figure 8.12. 8.13. Replace any part that shows wear or damage. NOTE: Whenever the bushings are re...

Section 6: Front Suspension 6 - 14 9.3. Remove the nut and bolt that hold the inner end of the axle assembly to the frame using two 15/16” wrenches. See Figure 9.3. NOTE: In some cases, one facet of the nut may rest up against a gusset on the rear bracket that bolt passes through. It may not be nece...

Section 6: Front Suspension 6 - 15 6 10. Steering Rack Removal and Replacement 10.1. Remove both front axle assemblies as described in the “Front Axle Assembly Removal and Replacement” section of this manual. See Figure 10.1. 10.2. Loosen the stop collar on the upper steering shaft using a 1/8” alle...

Section 6: Front Suspension 6 - 16 10.8. Remove the nuts and flat washers from both bolts that hold the steering sector bracket to the frame using two 9/16” wrenches. 10.9. Back the bolts part way out of the frame, leaving 1/4” to 3/8” clearance between the head of each bolt and the frame. 10.10. Pu...

Section 6: Front Suspension 6 - 17 6 NOTE: If a steering rack is sufficiently worn or damaged to require replacement, it makes sense to replace the tie rod ends as well. 10.14. To Install the steering rack in the Big Country, perform the following steps: 10.15. Center the new rack: Turn it to full l...

Section 6: Front Suspension 6 - 18 NOTE: In order to achieve proper alignment, it may be necessary to adjust the position of the steering rack on the steering sector bracket. This adjustment is the reason for the slotted mounting holes in the steering sector bracket. 10.25. Insert the clamp bolt thr...

Section 7: Electrical 7 - 1 7 1. Component Location 1.1. Battery : Under the hood on the right side 1.2. Regulator-Rectifier : Under the hood on the right side, immediately above the battery. See Figure 1.2. 1.3. The two fuse panels are located under the hood on the left side of the bulkhead. 1.4. T...

Section 7: Electrical 7 - 2 1.9. The key switch, hour meter, accessory switches*, warning lights, and front power port* , are located in the dash panel. * Where applicable 1.10. There is a bundle of wires at the rear of the vehicle to accommodate future installation of: • Electric Bed Lift • Light K...

Section 7: Electrical 7 - 3 7 1.13. The oil pressure switch is located on the back of the engine, near the oil filter. See Figure 1.13. 1.14. The fuel level switch is located in the fuel tank. See Figure 1.14. 1.15. There are a variety of wires leading to and com- ing from the engine. 1.16. The two ...