442/489 Series Conversions

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Arline Little
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1 442/489 Series Conversions October 31, 2014

2 Left Side of Trans. 5 6 Right Side of Trans

3 Rules of Conversion 3 Arrangement 5 Arrangement 3

4 Rules of Conversion 4 Observe and make notes. Observe and note the bearing cap position. The hub of the output gear is positioned above the input gear. Observe and note the position of the shift fork. The bearing shims are on the same side as the ratio gear. Observe and note the assembly arrangement position. Ratio gear tooth round faces the output gear not the input gear. Do not reuse snap rings. Torque shift cover and bearing cap bolts o Lbs. ft. o N.m. Torque idler shaft retainer o In. Lbs. o N.m. Roll input gear o No side to side sloppiness o P.T.O. Case should not left off the bench Output shaft o Should turn by hand. o In and out play at least.001 no more than.005 for best bearing end play.

Note relation of closed end bearing cap arrow to ratio letters on

5 Rules of Conversion Observe and make notes. Observe and note the bearing cap position. Note relation of closed end bearing cap arrow to ratio letters on housing. Note and mark output flange (open end) to correct ratio on housing. Closed End Open End 5 Gear Ratios

6 Rules of Conversion Observe and make notes. Observe that the hub of the output gear is positioned above the input gear. Output Gear Hub Input Gear 6

7 Rules of Conversion Observe and make notes. Observe and note the position of the shift fork. Shifter Fork Input Gear Output Gear Ratio Gear 7

8 Rules of Conversion Observe and make notes. Observe the bearing shims are on the same side as the ratio gear. Ratio Gear Shim 14-P-73-X Thrust Washer 31-P-102 8

9 Rules of Conversion Observe and make notes. Observe and note the assembly arrangement position. 9

10 Disassembly Shifter Cover Using a 1/2 socket remove the four bolts on the shifter cover. Remove the shifter cover and gasket. Inspect the condition of the gasket. 10

11 Disassembly Input Gear Section Remove the NWD plug from the idler shaft using a 3/16 hex wrench. Remove idler shaft while holding the input gear section. Remove complete input gear section. 11

12 Disassembly Closed End Remove the four (4) cap screws on the closed end bearing cap using a 1/2 hex wrench. Remove the bearing cap and gaskets. Inspect condition of gaskets and keep together. 12

13 Disassembly Closed End Bearing Removal Using a bearing puller set, remove the closed end bearing from the output shaft. Remove snap ring on the output shaft. DO NOT REUSE. 13

14 Caution and Reminder CAUTION: Never reuse a snap ring. Once it has been stretched it will not return to its original size. 14

15 Disassembly Output (Open) End Using a 1/2 hex wrench remove the four (4) open end hex head cap screws. Remove the output shaft and gear from the P.T.O. housing. Inspect gear and shaft for any nicks or wear. 15

16 Assembly 3 Arrangement 5 Arrangement 16

Assembly Output Section 3 Assembly Arrangement Make sure

17 Assembly Output Section 3 Assembly Arrangement Make sure the output gear matches the correct assembly arrangement of the P.T.O. The output gear shift hub is positioned above the Input gear in the engaged position. Slide output shaft into housing and slide output gear onto the shaft. U, W & X ratios will slide through the opening as an assembly. 17

Make sure that the snap ring is seated into the groove on the output shaft.

18 Assembly Output Section 3 Assembly Arrangement Using a snap ring slide or snap ring pliers install the snap ring onto the shaft. Make sure that the snap ring is seated into the groove on the output shaft. Install bearing onto closed end. REMINDER: Make sure the bearing is seated against the snap ring. Forgetting to do this can affect shaft end play. 18

Make sure the off set of the bearing cap is positioned correctly for the P.T.O.

19 Assembly Output Section 3 Assembly Arrangement Install gaskets. Install closed end bearing cap. Make sure the off set of the bearing cap is positioned correctly for the P.T.O. ratio. Using 1/2 hex wrench tighten and torque cap screws to Lbs. ft. [33-38 N.m.]. NOTE: Always use a crossing pattern when tightening bolts. 19

20 Assembly Output Section 3 Assembly Arrangement Make sure the off set of the bearing cap is positioned correctly for the P.T.O. ratio. NOTE: The narrow portion of the open end bearing cap matches the position of the arrow on the closed cap. 20

Assembly Output Section 3 Assembly Arrangement Using a

21 Assembly Output Section 3 Assembly Arrangement Using a seal slide. Install gaskets and open end cap/pump flange onto housing. Tighten and torque fasteners Lbs. ft. [ N.m.]. NOTE: Always use a crossing pattern when tightening the bolts. Check end play is set correctly between Can I turn the shaft by hand? 21

22 Assembly Ratio and Input Gear One Piece Input Gear Two Piece Input Gear Ratio Gear Snap Ring 22

23 Assembly Ratio and Input Gear Ratio Gear Input Gear Place the ratio gear on the splined surface of the input gear. NOTE: The rounded edge of the ratio gear should be away from the input gear. Snap Ring 23

24 Assembly Ratio and Input Gear Snap Ring Groove Snap Ring Slide Use a snap ring slide and driver or snap ring pliers to install the snap ring in the groove of the input gear. NOTE: Be careful to not over stretch the snap ring. 24

Assembly of Gear into Housing A = Input Gear

gear. NOTE: Tabs on washer and shims are

25 Assembly of Gear into Housing A = Input Gear B = Ratio Gear C = Output Gear Insert the thrust washer next to the input gear; place bearing shim on the same side as the ratio gear. NOTE: Tabs on washer and shims are placed in pocket on housing. Thrust Washer Shim 25

Assembly Input Section 3 Assembly Arrangement

Using a idler guide tool, insert complete

26 Assembly Input Section 3 Assembly Arrangement Note position of output gear in the engaged position. Shifter hub should be over P.T.O. input gear. Using a idler guide tool, insert complete input section into housing. No end to end play on output section. Gear turns freely. 26

shaft; be careful not to nick or cut the

27 Assembly Input Section 3 Assembly Arrangement Install O-Ring on idler shaft; be careful not to nick or cut the O-Ring. Slide the notched end of the shaft into the housing, aligning notch with roll pin. Install NWD plug on idler shaft and torque: In. Lbs. ( N.m.). Idler Shaft Notch O-Ring NOTE: Line on Idler Pin 27

Slide the shift block or fork onto the hub of the output gear.

28 Assembly Shifter Section 3 Assembly Arrangement Position output gear in the disengaged position. Position gasket and shift cover onto the P.T.O. housing. Slide the shift block or fork onto the hub of the output gear. Install capscrews and torque (16-20 Lbs. ft. [22 27 N.m.]) Do not over tighten you can break the shift cover or housing. Last function test the shifter and indicator switch. (80-90 PSI) 28

29 Final Steps Place P.T.O. on flat surface and spin the input gear. Gear should spin without lifting up housing. 29

30 Final Check Re-label P.T.O. All bolts and cap screws proper torque Testing o Function test shifter o Test indicator switch o Check end play of output shaft o Check input gear bearings Ready to install 30

31 Torque Specifications 442 Family Location Torque (English) Torque (Metric) NWD Plug In. Lbs N.m. Bearing Cap Open Lbs. ft N.m. Bearing Cap Pump Flange Lbs. ft N.m. Rotatable Flanges GA, GB, PA, PF, RA, RB, RE & RF ( ) (Qty. 3) RC, RD, RH ( ) (Qty. 6) RJ (Qty. 6), RY (Qty. 3) ( ) Lbs. ft N.m Lbs. ft N.m Lbs. ft N.m. Bearing Cap Closed Lbs. ft N.m. Shift Covers Lbs. ft N.m. 31

32 Corrected Torque with a Plus Dimension When using a torque wrench adapter which changes the distance from the torque drive to the adapter drive, apply the following formula to obtain torque rating. T = Actual (desired) torque Y = Apparent (indicated) torque L = Effective length lever E = Effective length of extension Adapter Drive Centerline Torque Wrench Wrench Drive Centerline Handgrip Centerline (Predetermined) Short Open End Adapters Set Screw Adapter FORMULA: T x L L + E = Y E L Hose Clamp Adapter 32

33 Corrected Torque with a Minus Dimension When using a torque wrench adapter which changes the distance from the torque drive to the adapter drive apply the following formula to obtain torque rating. T = Actual (desired) torque Y = Apparent (indicated) torque L = Effective length lever E = Effective length of extension Open End Wrench Adapter Wrench Drive Centerline Flare Nut Wrench Adapter Torque Wrench Adapter Drive Centerline Handgrip Centerline (Predetermined) Spanner Wrench Adapter FORMULA: T x L L - E = Y E L 33

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Chelsea Kit Program May 6, 2011

Chelsea Kit Program May 6, 2011 What is the KIT program? The Kit program provides you certain PTO s less the input gear or shift cover. It s purpose is to provide you with improved product coverage. Lowers