Text preview for : Chapter_09_Transmission.pdf part of Polaris Brutus HDPTO Polaris Brutus, Brutus HD, and Brutus HD PTO Service Manual Transmission
Chapter 09: Transmission
(Also Covers Bobcat 3600 and Bobcat 3650)
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TRANSMISSION
CHAPTER 9 TRANSMISSION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18.1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 ASSEMBLY VIEW / MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SHIFT LEVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 SHIFT CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
SHIFT LEVER / SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.36 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
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DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18 TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 SNORKEL SHAFT REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22 TRANSMISSION SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23 PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 8.27 PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29 SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
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TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12 TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
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SPECIFICATIONS
Torque Specifications
ITEM Bearing Retaining Plate Screws Bellcrank Nut Fill / Drain Plugs Gear Sector Cover Park Flange Screws Rear Transmission Isolator Mount Nut Engine to Transmission Mount Bolts Shift Fork Retaining Screws Snorkel Tube Snorkel Tube Locking Screw Differential Solenoid Transmission Case Screws Speed Sensor Screw TORQUE VALUE 8-10 ft-lbs (11-14 Nm) 12-18 ft-lbs (16-24 Nm) 10-14 ft-lbs (14-19 Nm) 9-12 ft-lbs (12-16 Nm) 8-10 ft-lbs (11-14 Nm) 22 ft-lbs (30 Nm) 47 ft-lbs (64 Nm) 7-10 ft-lbs (10-14 Nm) Refer to "Snorkel Gear Backlash Procedure" 8-10 ft-lbs (11-14 Nm) 25 ft-lbs (34 Nm) 15-20 ft-lbs (20-27 Nm) 9-12 ft-lbs (12-16 Nm)
Special Tools
PART NUMBER PA-50231 2871698 (Part of 2871702 Kit) 2871699 (Part of 2871702 Kit) 2871282 TOOL DESCRIPTION Snorkel Tool Rear Output Seal Driver Rear Driveshaft Seal Guide Bearing Seal Driver (50 mm)
Lubrication
Transmission Mounting and Torque Values
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47 ft-lbs (64 Nm)*
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22 ft-lbs (30 Nm)
Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity: 41 oz. (1200 ml)
* Reference "Transmission Installation" procedure for torque sequence.
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40 ft-lbs (54 Nm) 47 ft-lbs (64 Nm)*
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
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SHIFT LEVER / SHIFT CABLE
Assembly View / Mounting
40 in-lbs (4.5 Nm) Knob
Cover
Bushing
Shift Lever
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Bushing Retaining Ring Shift Cable
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Bracket
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13 ft-lbs (18 Nm)
18 ft-lbs (24 Nm)
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37 ft-lbs (50 Nm)
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13 ft-lbs (18 Nm)
13 ft-lbs (18 Nm)
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Shift Lever Removal / Installation
1. Remove the four push rivets (Item 1) retaining the upper dash panel (Item 2). Remove the panel to access the shift lever mounting. 1 1 4. Remove clip (Item 8) and washer (Item 9) retaining the shift cable (Item 10) to the shift lever (Item 11). Disconnect cable end from the lever. 11
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2. Remove the shift knob cover (Item 3), retaining screw (Item 4) and shift knob (Item 5) from the shift lever (Item 6). 3 4
5. Remove the retaining ring (Item 12) and slide the shift lever off the mounting bracket and out from the frame. 6. Remove both bushings (Item 13) from the shift lever and service as needed. 7. Perform the previous steps in reverse order to reinstall the shift lever (lever, cable, grommet, shift knob, dash panel).
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3. Remove the rubber grommet (Item 7) from the dash.
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Shift Cable Inspection / Adjustment
Shift cable adjustment may be necessary if symptoms include: · No gear position or AWD display on gauge cluster · Ratcheting noise on deceleration · Inability to engage into a gear · Excessive gear lash (noise) · Gear selector moving out of desired range 1. Locate the shift cable (Item 1) attached to the mount bracket (Item 2) and transmission in the right rear wheel well area. 2. Inspect shift cable dust boot (Item 3) and the clevis pin and pivot bushings (Item 4). Replace if worn or damaged. 4 3 5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTE: This procedure may require a few attempts to obtain the proper adjustment. 6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut (Item 5) against the mount. 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.
Shift Cable Replacement
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1. Remove the four push rivets (Item 1) retaining the upper dash panel (Item 2). Remove the panel to access the shift cable mounting. 1
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3. If shift cable adjustment is required, loosen the lower jam nut (Item 5) and pull the cable out of the mount bracket to move the upper jam nut (Item 6). 6
2. Remove clip and washer (Item 3) retaining the shift cable (Item 4) to the shift lever (Item 5). Disconnect cable end from the lever.
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4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK.
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3. Loosen the lower jam nut (Item 6) and pull the shift cable out of the mount bracket (Item 7).
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4. Locate the shift cable in the right rear wheel well. 5. Remove the clevis pin (Item 8) and remove the shift cable from the transmission bellcrank (Item 9). 8 8. Remove the push rivets retaining the drive shaft cover and remove the cover to access the shift cable (Item 12).
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6. Loosen the lower jam nut (Item 10) and pull the shift cable out of the mount bracket (Item 11).
9. Remove the shift cable from the vehicle. 10. Route the new shift cable same as previously removed. Be sure to route the shift cable together with the brake line (Item 13) in the area under the driveshaft cover as previously shown. 11. When installation is complete, adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK (see "Shift Cable Inspection / Adjustment").
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7. Remove the fasteners retaining the skid plate and remove the skid plate to access the shift cable.
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TRANSMISSION REMOVAL
CAUTION
Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this procedure. Always wear eye protection. 1. Elevate the vehicle and safely support the vehicle under the frame area. 2. Remove the rear "Maintenance"). wheels (see Chapter 2 5 6. Loosen the intake hose clamp (Item 5).
3. Remove the hydrostatic drive motor from the transmission (see Chapter 10 "Hydrostatic Drive"). 4. Loosen the airbox hose clamps (Item 1) and remove the hose (Item 2).
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7. Remove the two bolts (Item 6) and intake plenum (Item 7).
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8. Disconnect the speed sensor (Item 8) and the box harness connectors (Item 9). 8
5. Remove the two airbox bolts (Item 3) and remove the airbox (Item 4).
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9. Disconnect the gear indicator connector (Item 10). 12. Remove the two bolts (Item 14) retaining the brake caliper. Repeat for the other side.
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13. Remove the brake line from the clips (Item 15).
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11. Remove two bolts (Item 13) retaining the cable mount.
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14. Remove the two screws (Item 16) retaining the brake line junction block. 16
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10. Remove the clip (Item 11), washer and shift cable (Item 12) from the transmission.
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15. Reposition the calipers and brake lines to prevent damage. 16. Remove the wheel bearing dust cover (Item 17) from each wheel hub. 18. Remove the bolt and nut (Item 21) retaining the lower suspension arm to the axle brace. (Both Sides)
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17. Remove the cotter pin (Item 18), nut (Item 19) and washer (Item 20) from each wheel hub.
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19. Remove the nut and bolt (Item 22) from the suspension pivot and remove the rear axle brace.
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20. Remove each rear drive shaft using short, sharp pulls to free the circlip from the vehicle.
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21. Remove the roll pin (Item 23) from the front prop shaft. 24. Remove the bolts (Item 26) from the engine speed control cable bracket.
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22. Remove the bolts (Item 24) from the front gear box. Slide the gear box towards the front of the vehicle allowing the drive shaft to slide off the splined shaft.
25. Remove the end of the engine speed control cable (Item 27) from the pump linkage. Reposition the cable to prevent damage. 26. Support the rear of the transmission.
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23. Slide the drive shaft (Item 25) off the transmission output shaft.
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27. Support the rear of the engine to prevent the engine from tipping backwards when the rear transmission mount bolt is removed. 30. Remove the four right side mount bolts (Item 30) and spacer block (Item 31).
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28. Remove the nuts (Item 28) from the rear transmission mount.
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NOTE: Remove the engine oil filter (Item 32) to aid with fastener removal. Reinstall the oil filter once the upper fastener has been removed. 31. With the help of an assistant, manually lift and turn the transmission to get it out of the vehicle. 32. Remove the transmission.
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31 28 29. Remove the two left side mount bolts (Item 29).
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TRANSMISSION INSTALLATION
CAUTION
Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this procedure. Always wear eye protection. 1. Lift and tilt the transmission to reinstall it. 2. Support the rear of the engine to ease transmission mount bolt installation. 4 4. Install the two mounting bolts (Item 4) and washers (Item 5) on the left side of the transmission. Torque the two left side fasteners to specification.
3. Loosely install the two fasteners (Item 1) retaining the spacer block (Item 2) to the transmission on the right side of the transmission. NOTE: Remove the engine oil filter to aid with fastener installation. Reinstall the oil filter once the upper fastener has been installed.
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5. Install the remaining two fasteners (Item 6) and washers (Item 7) on the right side of the transmission. Torque the bottom fastener to 5 ft-lbs. (6.8 Nm) in order to prevent any pre-stress on mounting components during the final torque procedure.
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Engine to Transmission Mounting Bolts: 47 ft-lbs (64 Nm)
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1 NOTE: Install the washers (Item 3) on the nut side (drive side).
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6. Torque the four fasteners on the right side of the transmission to specification in the sequence shown. 8. Install the end of the engine speed control cable (Item 9) into the pump linkage.
#2
#1 #4
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IMPORTANT: Be sure to torque fastener #1 and #2 from the nut side.
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Engine to Transmission Mounting Bolts: 47 ft-lbs (64 Nm)
7. Install the nuts (Item 8) onto the rear transmission mount. Torque nuts to specification.
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9. Install the bolts (Item 10) that retain the engine speed control cable bracket. 10. Lubricate the splines with an anti-seize compound and slide the drive shaft (Item 11) onto the transmission output shaft.
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Rear Transmission Mount Nut: 22 ft-lbs (30 Nm)
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11. Line up the splines on the front gearcase to the prop shaft. Line up the front gearcase with the mounting holes and install the mounting bolts (Item 12). Torque bolts to specification. 14. Install the rear axle brace and install the nut and bolt (Item 14) for the rear suspension pivot. Torque bolt to specification.
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Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 12. Install a NEW roll pin (Item 13) in the front prop shaft.
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15. Install the bolt and nut (Item 15) retaining the lower suspension arm to the axle brace on both sides. Torque the bolts to specification.
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Upper Suspension Link to Rear Axle Brace Bolt: 40 ft-lbs (54 Nm)
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13. Lubricate the splines with an anti-seize compound and install both rear drive shafts into the transmission.
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Rear Axle Brace to Lower Suspension Link Bolt: 40 ft-lbs (54 Nm)
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16. Install rear hubs, washer, nut and NEW cotter pin. Torque nuts to specification. 20. Install the brake caliper and mounting bolts (Item 18) on each wheel hub. Torque the mounting bolts to specification.
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Rear Axle Nut: 110 ft-lbs (149 Nm) 17. Install the wheel bearing dust cover on both sides. 18. Install the two screws (Item 16) retaining the brake line junction block. Torque screws to specification.
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Brake Caliper Mounting Bolts: 30 ft-lbs (41 Nm)
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Brake Line Junction Block Screws: 35 in-lbs (4 Nm)
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21. Install the two shift cable mount bolts (Item 19). Torque bolts to specification.
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Transmission Shift Cable Mount Bolts: 37 ft-lbs (50 Nm)
19. Secure all rear brake lines into the clips (Item 17).
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22. Install the shift cable, washer and clip (Item 20), on the transmission. 25. Install the intake plenum and torque the mounting bolts (Item 24) to specification.
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23. Connect the gear switch harness (Item 21).
26. Tighten the intake hose clamp (Item 25).
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24. Connect the speed sensor (Item 22) and the box harness connectors (Item 23).
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Intake Plenum Mounting Bolts: 4 ft-lbs (5.4 Nm)
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27. Install the airbox and tighten the mounting bolts (Item 26) to specification. 30. Install the wheels and torque the wheel nuts to specification (see Chapter 2 "Maintenance").
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Airbox Mounting Bolts: 8 ft-lbs (10.8 Nm) 28. Install the intake hose and tighten the airbox hose clamps (Item 27).
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29. Install the hydrostatic drive motor to the transmission (see Chapter 10 "Hydrostatic Drive"). Torque mounting bolts to specification.
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Hydrostatic Motor Mounting Bolts: 100 ft-lbs (136 Nm)
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Differential Operation
The transmission has two traction operational modes: Differential Lock and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions. Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain. When switch position is set to "Unlock", the solenoid is powered and the plunger extends to disengage the side gear and unlock the differential.
AWD
Differential - Lock
Differential - Unlock
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Planetary Differential Components
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Shift Fork Retainer Spring Solenoid Torsion Spring Bearing Engagement Dog Planetary Differential Assembly
When "Differential-Unlock" is selected, the rear differential becomes unlocked for tighter turns. An electrical solenoid mounted in the rear portion of the gearcase actuates the shift fork. The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly. This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns.
When switch position is set to "Lock", power is removed from the solenoid and spring tension retracts the plunger to engage the clutch gear and lock the differential.
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Male Side Gear Assembly Ring Gear Assembly
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Differential Cover Assembly Screw Female Side Gear Assembly
Planet Gear Assembly
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When "Differential-Lock" is selected, power is removed from the electrical solenoid allowing the solenoid plunger to retract. Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is part of the planetary differential assembly. This locks the rear differential as a solid rear axle, increasing traction.
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Transmission Disassembly
NOTE: Refer to the exploded view at the end of this chapter as a reference. 1. Drain and properly dispose of the transmission lubricant (see Chapter 2). 2. Remove the bellcrank nut (Item 1) and bellcrank (Item 2). 7 1 6 2 6. Remove the detent star (Item 9). Note how the detent star fits onto the splined shaft with the skip tooth aligned and tall center hub facing inward for reassembly. 7. Remove the shift shaft (Item 10), detent pawl (Item 11) and the shift sector gears (Item 12).
9. Remove all the transmission case bolts. Using suitable pry bars, remove the cover using the designated pry points (indicated by the black arrows in the illustration below).
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3. Remove E-clip (Item 3) that retains spring and flat washers (Item 4), and gear switch (Item 5). Remove the switch.
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4. Remove the sector cover bolts (Item 6) and remove the sector cover (Item 7).
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CAUTION
Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. shift fork pins and remove the shift drum from the
5. Remove the compression spring (Item 8).
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13 9 10. Lift up on the shift drum (Item 14) to disengage the
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NOTE: Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers.
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8. Remove the O-rings (Item 13) from each shaft and discard. Use new O-rings upon assembly.
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IMPORTANT: Note the timing marks on the shift gears for reassembly purposes.
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housing. 14 transmission housing by pulling straight up.
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11. Lift up to remove the shift shaft rail (Item 15) and shift forks from the transmission housing as an assembly.
14. Remove the gear cluster assembly (Item 18) and idler gear shaft assembly (Item 19) from the transmission housing by pulling both assemblies straight up. 19
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12. Remove the rear output shaft assembly (Item 16) by lifting underneath the gear or by tapping the shaft from the opposite side. If use of a pry bar is necessary, take care not to pry on sealing surfaces of case.
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15. Inspect the gear cluster assembly and idler gear shaft assembly. Inspect each gear for damage, chips or abnormally worn teeth. Replace bearings if needed. If disassembly is required, refer to "Transmission Shaft Service".
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Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury.
13. Remove the input shaft assembly (Item 17) from the
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16. To disassemble the shift shaft rail remove the snap ring (Item 20) from the end of the shift rail on either side. Refer to "Transmission Shaft Service" if needed. 19. Using a 5 mm Allen wrench, remove the screws that secure the pinion shaft assembly (Item 23). Lift the pinion shaft assembly straight up to remove it from the housing. Note the longer screw (Item 24) that locks the snorkel tube. 23 20 20 24
17. Slide engagement dog (Item 21) off of shift fork guides.
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20. If snorkel shaft removal is not required, remove all seals from the gearcase halves and clean the cases in preparation for assembly. 21. If snorkel shaft removal is required, proceed to "Snorkel Shaft Removal / Disassembly" procedure.
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18. Remove two screws and retaining plates, then lift the shift fork (Item 22) and torsion spring out of transmission housing.
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Snorkel Shaft Removal / Disassembly CAUTION
The pinion shaft must be removed prior to removing the snorkel shaft assembly. Failure to remove pinion shaft, will result in damage to the snorkel shaft. 22. Extract the seal from the snorkel shaft to access the snorkel tube for removal. 24. Remove the snorkel tube and shaft assembly from the transmission case.
25. Remove the snap ring (Item 1) and shim (Item 2) from the snorkel shaft.
Seal Removed
23. Using the Snorkel Tool (PA-50231), fully loosen the snorkel tube.
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26. Use an arbor press to remove the snorkel tube from the snorkel shaft. 27. Remove the snap ring (Item 3) and shim (Item 4) retaining the bearing in the snorkel tube.
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28. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube.
Transmission Shaft Service
Use the exploded views within this section when servicing the transmission shafts. Inspect all gear sets and shafts for excessive wear or damage. IMPORTANT: If gear replacement is required, be sure to also replace the corresponding gear or gear shaft.
Gear Cluster / Reverse Shaft Assembly
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Inspect all bearings for signs of wear or damage. If replacement is required, use a standard bearing puller or an arbor press.
29. Remove the retaining ring to remove the remaining washer, bearing and gear from the snorkel shaft.
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6 4 2 3 1 1) Bearing 2) Shift Dog, Park 3) Retaining Ring 4) Washer 5) Needle Bearing 6) Low Gear, 67T 7) Reverse Shaft, 35T 8) Engagement Dog, 6-Face 9) Retaining Ring 10) Washer 11) Gear, 52T 12) Needle Bearing 13) Washer 14) Retaining Ring 15) Bearing
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30. Remove all seals from the gearcase halves and clean the cases in preparation for assembly.
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Idler Shaft Assembly 21 19 29 17 20 26 32C Pinion Shaft Assembly 34
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16 16) Bearing 17) Idler Shaft 18) Gear, 38T 19) Washer 20) Retaining Ring 21) Bearing Input Shaft Assembly
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22) Bearing 23) Input Shaft 24) Bearing
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22
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25) Bearing 26) Retaining Ring 27) Washer 28) Gear, 46T 29) Screw, M6 x 1.0 x 18 30) Screw, M6 x 1.0 x 40 31) Bearing Cover 32) Retaining Ring 33) Bearing 34) Pinion Shaft
A Longer B
Bearing cover must be installed on the shaft before installing the 46T gear.
C
Bevel side should face away from the bearing.
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27 25 screw is used to lock the snorkel tube.
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33 31B 30A
N
28
TRANSMISSION
Shift Shaft Assembly 35 38 40 Snorkel Shaft / Snorkel Tube Assembly 42* 44*
36 43*
46*
38 41 36 37 35 35) Retaining Ring 36) Cup Washer 37) Shift Shaft Rail 38) Compression Spring, Long 39) Shift Fork 40) Compression Spring, Short 41) Shift Collar 39 39
45*
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47
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42) Retaining Ring 43) Washer 44) Bearing 45) Snorkel Gear, 13T 46) Front Output Shaft 47) Snorkel Tube 48) Bearing 49) Shim 50) Retaining Ring 51) Shim 52) Retaining Ring
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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*After the 13T gear and bearing are pressed onto the snorkel shaft (flush to the shoulder), install the washer and new retaining ring. Press the gear back towards the retaining ring. Avoid excessive force so the retaining ring is not damaged or pre-stressed significantly. IMPORTANT: Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service.
N
48 50 51 49 52
9
PR
EL
9.25
TRANSMISSION
Planetary Differential Disassembly
NOTE: If the gearcase is completely assembled, perform the "Gearcase Disassembly and Inspection" procedure. 1. Use a scribe to mark the differential cover and ring gear prior to disassembly. Scribe 3. Remove the six planet gears and each side gear assembly from the ring gear. Planet Gears
2. Remove the six screws retaining the differential cover and remove the cover.
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1 3 4
4. Inspect the female side gear (Item 1), male side gear (Item 2), planet gears (Item 3) and ring gear (Item 4). Replace components or bushings as needed. Bushing replacement can be performed on all necessary differential components. If bushing replacement is required, proceed to Planetary Differential Bushing Replacement". 2
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9.26
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Side Gear 3
TRANSMISSION
Planetary Differential Bushing Replacement
NOTE: If the differential is completely assembled, perform the "Planetary Differential Disassembly" procedure. Ring Gear Bushing Replacement 1. Press the old bushing out of the ring gear. 2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 3. Press the new bushing into the ring gear housing. 4. Install the bushing to the specified depth as shown. Install bushing flush to .039 in. (1 mm) recessed from end face of hub
Bushing
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New Bushing Planet Gear Bushing Replacement 1. Press the old bushing out of the planet gear. 2. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 3. Press the new bushing into the planet gear until it is flush on each end. Repeat this procedure for the remaining planet gears.
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9
9.27
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Differential Cover Bushing Replacement 1. Press the old bushing out of the differential cover. 2. Thoroughly clean the bore of the differential cover and check for any unwanted burs. 3. Press the new bushing into the differential cover. Female Side Gear Bushing Replacement 1. Locate the bushing split. Using a small chisel or flat blade screwdriver, peel back and remove the old bushing from the side gear, being careful not to damage the side gear. Bushing Split Peel Back Here
2. Thoroughly clean the bore of the side gear and check for any unwanted burs. 3. Press the new bushing into the side gear until it bottoms out.
4. Install the bushing to the specified depth as shown.
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TRANSMISSION
Planetary Differential Assembly
1. Thoroughly clean the differential components. 2. Assemble the side gears and place them onto the ring gear along with the six planet gears. Planet Gears
Snorkel Gear Backlash Procedure
1. Reassemble the snorkel tube and snorkel shaft assembly by reversing the disassembly procedure (see "Snorkel Shaft Removal / Disassembly"). 2. After the 13T gear and bearing are pressed onto the snorkel shaft (flush to the shoulder), install the washer and new retaining ring. 3. Press the gear back towards the retaining ring. Avoid excessive force so the retaining ring is not damaged or pre-stressed significantly. IMPORTANT: Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service.
3. Align and install the differential cover using the previously made scribe marks. 4. Apply Loctite® 2760TM to cover screws. 5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification.
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Side Gear
4. Apply a small amount of white lithium grease or AntiSeize on the threads of the snorkel tube. Grease Threads
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PA-50231
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PR
Differential Cover Screws: 18-22 ft-lbs (24-30 Nm)
IM
5. Install the snorkel shaft into the gearcase. Using the Snorkel Tool (PA-50231), tighten the snorkel tube until it is lightly seated in the transmission housing.
9
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TRANSMISSION
6. Inspect the pinion shaft assembly. Replace bearings if needed. Inspect each gear for damage, chips or abnormally worn teeth. If disassembly is required, refer to "Transmission Shaft Service". NOTE: If pinion shaft was disassembled, the bearing cover must be installed on the shaft before installing the 46T gear. 7. Install the pinion shaft assembly. Be sure to properly mesh the snorkel shaft bevel gear with the pinion shaft bevel gear. 8. Apply Loctite® 242TM to the threads of the bearing cover retaining screws. 9. Using a 5 mm Allen wrench, install only the (3) screws that secure the pinion shaft assembly as shown below. Leave the longer locking screw (A) out at this point. A 11. Rotate the snorkel tube counterclockwise using the snorkel tool (PA-50231) until the snorkel gear and pinion gear have `zero' backlash. IMPORTANT: DO NOT overtighten the snorkel tube when backing it out. At the 'zero' backlash position, you should still be able to turn the snorkel shaft using your fingers, but it will feel rough and may have some tight spots. 12. Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point.
13. Slowly rotate the snorkel tube clockwise while counting the number of notches passing through the hole opening as you rotate the tube. Rotate the snorkel tube to the 3rd notch from the `zero' backlash position obtained in step 11. Count 3 notches through the locking screw hole
DO NOT install locking screw
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10. Torque the bearing cover retaining screws to specification.
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IMPORTANT: DO NOT install the longer screw (A). Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment. 14. Check the pinion shaft gear backlash again by feel. If the pinion shaft gear lash appears to be too tight, rotate the snorkel shaft clockwise to the next notch (4th notch).
=T
Bearing Cover Retaining Screws: 8-10 ft-lbs (11-14 Nm)
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NOTE: If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole.
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15. Once the backlash is set, apply Loctite® 242TM to the threads and install the locking screw to secure the snorkel tube.
16. Torque the locking screw to specification. 8-10 ft-lbs (11-14 Nm)
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9.31
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Snorkel Locking Screw: 8-10 ft-lbs (11-14 Nm)
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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TRANSMISSION
Transmission Assembly
IMPORTANT: The snorkel shaft and pinion shaft must be installed prior to transmission assembly. The snorkel shaft cannot be installed after assembling the transmission. 1. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 2. Install the input shaft seal (Item 1) into the transmission LH case half. The seal, should be pressed in until it is flush with the internal bearing surface as shown. 4. Apply Loctite® 242TM to two screws (Item 3) and install with retaining plates over shift fork. Torque to specification.
=T
Shift Fork Screws: 7-10 ft-lbs (10-14 Nm) 5. Slide the engagement dog (Item 4) onto retaining pins of shift fork.
6. Assemble the gear cluster assembly and idler gear shaft assembly if previously disassembled (see "Transmission Shaft Service").
1
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5 7
7. Install the gear cluster assembly (Item 5) and idler gear shaft assembly (Item 6) into the transmission housing at the same time. 6
3. Install shift fork (Item 2) and torsion spring into transmission housing as an assembly. Load spring as shown in image below
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4 8. Install the input shaft assembly (Item 7) into the transmission housing.
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TRANSMISSION
9. Install the rear output shaft assembly (Item 8). Rotate output shaft assembly to align slots with engagement dog. Ensure bearing is fully seated upon assembly. 8 11. Install the shift shaft rail (Item 10) and shift forks into the transmission housing as an assembly. Be sure the shift forks are engaged into the engagement dogs. 10
10. Assemble shift shaft rail if previously disassembled. 9
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NOTE: Shift fork pins should be offset towards the input shaft as shown above.
12. Inspect the shift drum for any damage or wear. Inspect the splines of the shift drum.
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NOTE: Both shift forks need to be orientated the same way, so that the shift fork pins (Item 9) are both offset to the same side of the rail.
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9
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13. Install the shift drum (Item 11) into the transmission housing. Lift up on the shift shaft rail and move the rail assembly towards the shift drum to allow the shift fork and collar pins to be installed into the shift drum. 16. Install new seals into the transmission case halves. NOTE: The input shaft seal (Item 13), should have been installed during Step 2. The seal must be pressed in until it is flush with the internal bearing surface, which can not be seen with the transmission assembled.
11
· The rear output shaft seals (Item 15), can be installed using a standard bushing installation tool. Seals should be installed just past the case lead-in chamfer (.070" or 1.8 mm from outer face of bore). 15
14. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. 15. Install the transmission case cover and retaining bolts. Torque bolts to specification. 12
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14 15
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12
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NOTE: Six of the case bolts (Item 12) are longer than the rest. These bolts are used to retain the motor flange at the input shaft location and to retain the rear mount brackets to the transmission.
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Transmission Case Bolts: 15-20 ft-lbs (20-27 Nm)
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17. Thoroughly clean the shift shaft housing. Shift the transmission into High gear to ease assembly.
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13
· The snorkel shaft seal (Item 14), should be pressed in until it seats against the housing counter-bore.
TRANSMISSION
18. Install the sector gear (16T) onto the shift drum shaft. Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks (Item 16) on the gears as shown (high gear). 21. Install a new O-ring (Item 20) on each shift shaft. Apply a small amount of white lithium grease on the O-rings, shift shafts and component contact surfaces prior to installing the sector cover.
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20 17
16
19. Install the detent star (Item 17) onto the shift drum shaft. Be sure to install the detent star with the tall center hub facing inward and skip-tooth aligned.
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19
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22. Clean the transmission and gear sector cover mating surfaces thoroughly. 23. Apply Crankcase Sealant (3-Bond) (PN 2871557) onto the cover and transmission case mating surface. 24. Install the sector cover and align the transmission case dowel (Item 21) with the alignment hole. Install and torque the bolts to specification.
=T
Sector Cover Bolts: 9-12 ft-lbs (12-16 Nm)
IN
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21
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18
25. Install the drain plug and torque to specification.
9
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20. Install the detent pawl (Item 18) onto the shift shaft and carefully install the compression spring (Item 19).
=T
Fill / Drain Plug: 10-14 ft-lbs (14-19 Nm) 26. Install the bellcrank onto the shift shaft. Note the key splined on the bellcrank and shift shaft. Install the nut and torque to specification.
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=T
Bellcrank Nut: 12-18 ft-lbs (16-24 Nm) 27. Reference "Transmission Installation" to complete repair.
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18-22 ft-lbs (24-30 Nm) 2760 TM
FOR REASSEMBLY
Apply White Lithium Based Grease.
TRANSMISSION
Apply Polaris Crankcase Sealant.
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TRANSMISSION EXPLODED VIEW
Apply Loctite® to the bolt threads.
EL IM IN
7-10 ft-lbs (10-14 Nm) 25 ft-lbs (34 Nm) 15-20 ft-lbs (20-27 Nm)
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242 TM 8-10 ft-lbs (11-14 Nm) 242 TM
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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Refer to "Snorkel Gear Backlash Procedure"
10-14 ft-lbs (14-19 Nm) 9-12 ft-lbs (12-16 Nm) 15-20 ft-lbs (20-27 Nm) 10-14 ft-lbs (14-19 Nm)
12-18 ft-lbs (16-24 Nm)
15-20 ft-lbs (20-27 Nm)
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Exploded View, Continued
Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. Qty. 1 1 3 11 6 6 1 6 2 1 2 2 1 1 2 1 1 1 1 1 1 2 2 2 1 2 1 1 1 1 2 1 2 3 1 1 2 1 Fill Plug Drain Plug, Magnetic Screw, M8 x 1.25 x 16 Screw, M8 x 1.25 x 30 Screw, M6 x 1 x 20 Screw, M8 x 50 Screw, M6 x 1 x 40 Screw, M6 x 1 x 18 Screw, M6 x 1 x 16 Nut, NyLoc, M8 x 1.25 Washer, Cup Washer Washer Washer Pin, Dowel Pin, Spring Retaining Ring, External Snap Ring Retaining Ring, External Retaining Ring, External Retaining Ring, Internal Retaining Ring, External Retaining Ring, External Retaining Ring, External Retaining Ring, External Washer, Thrust Washer, Thrust Shim Shim Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Needle Cage Description Ref. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Gear, Sector 16T Gear, Sector 31T Pawl, Detent Star, Detent Flange, Motor Shaft, Reverse 35T Shaft, Front Output Shaft, Input Helical Shaft, Pinion Bellcrank Shaft, Idler 29T Description
Plate, Park, 12-Face Collar, Shift
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71. 72. 73. 74. 75. 76. 77. 79. 80. 81. 83. 84. 85. 86. 87. 88. 89. 90. 91. 93. 97. 98. 99. 100. 101. 102. 103. 104.
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Tube, Vent, 1/4 in. Fork, Pivot Shaft Shift Dog, Park Fork, Shift Dog, Engagement Gear, 38T 65. 1 66. 68. 1 1 67. 1 69. 2 70. 1 1 1 1 1 1 1 1 2 1 1 6 1 1 1 1 1 1 1 2 1 2 1 3 1 1 6 6 1 Gear, Low 67T Gear, 52T Gear, 46T Gear, Snorkel 13T Shaft, Shift Retainer, Fork Bearing, Plain Solenoid O-Ring O-Ring O-Ring Seal, Triple Lip Seal, Dual Lip Seal, Triple Lip Sensor, Speed Plug, Expansion Bearing, Plain Diff Cover Planet Gear Ring Gear, 53T 9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
Rail, Shift Shaft
Bracket, Wire Harness
Engagement Dog, 6-Face
Weldment, Rear Mount Bracket Bracket, Rear Mount Cover, Bearing, Center Drive
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9.37
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Switch, Rotary, 2-Pin
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43. 44. 45. 46. 47. 48. 49.
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Bearing, Needle Cage
2 2
Spring, Compression Spring, Compression
1
Spring, Torsion Return Spring, Compression, Detent Spring, Washer
1
Spring, Compression
1
Side Gear, Male, 39T Side Gear, Female, 39T
1
1 1 1 1 1
Snorkel Tube Cover, Sector Gears Case, LH Case, RH Drum, Shift
Screw, M8 x 1.25 x 25
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TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is encountered. · Shift cable adjustment/condition · Vehicle creep (travel control adjustment) · Transmission lubricant type/quality · Loose fasteners on sector gear cover · Worn rod ends, clevis pins, or pivot arm bushings · Shift selector rail travel · Worn, broken or damaged internal transmission components
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NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting the shift cable end from the transmission bellcrank. Manually select each gear range at the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
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