Cub Cadet Big Country 2004 Service Manual

MTD Products Inc. - Product Training and Education DepartmentFORM NUMBER - 769-0163512/20044x2 Utility VehiclePoly Bed and Steel BedNOTE: These materi

Poly Bed 4 X 2 Drive System 6Shift Control Adjustment4.20. To adjust the shift cable, use the neutral safety switch to confirm the neutral position.

Poly Bed 4 X 2 Drive System 7Differential Lock ControlIn normal operation, a differential allows the two rear wheels to rotate at different speeds. I

Poly Bed 4 X 2 Drive System 84.34. If the linkage binds, disconnect the cable to iso-late the external portion of the linkage from inter-nal transaxle

Poly Bed 4 X 2 Drive System 94.40. Tighten the cable bracket mounting bolts to a torque of 78 in-lb. (8.8 N-m) on installation. 4.41. The cable is sec

Poly Bed 4 X 2 Drive System 104.48. With the bracket removed, the fuel tank can be moved far enough back to allow the clevis pin to be removed. See Fi

Poly Bed 4 X 2 Drive System 115. DIAGNOSIS AND SERVICE: DRIVE BELT AND CLUTCHES (CVT OR CONTINUOUSLY VARIABLE TRANSMISSION)5.1. Performance problems s

Poly Bed 4 X 2 Drive System 12Inspection5.3. Park the vehicle on a firm level surface, with the ignition turned off, and lift the load bed to provide

Poly Bed 4 X 2 Drive System 135.12. Loosen the hose clamp that secures the molded hose from the air filter to the plenum. See Figure 5.

Poly Bed 4 X 2 Drive System 145.19. Inspect the belt and clutches (pulleys) for obvi-ous damage and wear: See Figure 5.19.• The belt should measure at

Poly Bed 4 X 2 Drive System 155.25. Confirm that the throttle cable, and the travel stops on the throttle cable are adjusted to pro-vide the full rang

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Poly Bed 4 X 2 Drive System 165.29. Hold the throttle arm against the stop screw. Adjust the stop screw to set the engine speed to 1,100 RPM + 50. 5

Poly Bed 4 X 2 Drive System 175.35. As the driving pulley compresses the belt, it is forced outward in the tapered sheave. NOTE: As the effective dia

Poly Bed 4 X 2 Drive System 185.44. If it is necessary to hold the crankshaft from turn-ing: choose one of three methods. See Figure

Poly Bed 4 X 2 Drive System 195.50. After the belt is removed, the driven pulley can be removed: See Figure 5.50.• Take the bolt and washer that secur

Poly Bed 4 X 2 Drive System 205.57. Beyond the warranty period, if a dealer chooses to service a driven clutch, service information and specialized to

Poly Bed 4 X 2 Drive System 216.6. Lift the bed. Remove the exhaust pipe and the CVT assembly, including the housing, as described in the CVT section

Poly Bed 4 X 2 Drive System 226.13. Remove and discard the cotter pins securing the clevis pins into each brake cable clevis/actuator arm connection.

Poly Bed 4 X 2 Drive System 236.19. Jackstands must be placed under the frame, not the engine/transaxle cradle. See Figure 6.19.NOTE: The cross member

Poly Bed 4 X 2 Drive System 247. TRANSAXLE INSTALLATION NOTES:7.1. Reverse the removal procedure to install the transaxle. The following items are tip

Poly Bed 4 X 2 Drive System 25NOTE: 1 May be inaccessible with torque wrench.NOTE: 2If locking feature on nut is worn, replace the nut or apply relea

Poly Bed 4 X 2 Drive System Customer Responsibilities ... 1G

Poly Bed 4 X 2 Drive System 268.6. Remove the nut and bolt (top) that connect the link assembly to the frame using a pair of 15/16” wrenches. See Figu

Poly Bed 4 X 2 Drive System 279.5. After the wheels and brake drums are removed from the axle shafts, remove the brake shoes as described in the “Brak

Poly Bed 4 X 2 Drive System 289.9. When placed on the bench, take note of the ori-entation of the transaxle components. Match marks will ease the ass

Poly Bed 4 X 2 Drive System 299.15. The axle shaft will slip out of the collar. The groove on the collar engages the pin on the shift arm9.16. The ax

Poly Bed 4 X 2 Drive System 309.20. Remove the seal from the axle tube. See Figure 9.20.NOTE: The oil seal seats against a shoulder in

Poly Bed 4 X 2 Drive System 31Transaxle housing and internals:9.26. Prepare to separate the case: Clean any rust or burrs from the input shaft with e

Poly Bed 4 X 2 Drive System 329.31. Clean the left half of the housing, and inspect the three bearings that reside in it. See Figure 9.31.• The larges

Poly Bed 4 X 2 Drive System 339.35. Lift the 51-tooth sprocket off of the reduction shaft along with the 19-tooth sprocket from the input shaft and th

Poly Bed 4 X 2 Drive System 349.40. Use a magnet to remove the pin that retains the shift lever. See Figure 9.40.9.41. After the pin is removed, slide

Poly Bed 4 X 2 Drive System 359.46. Like the input shaft, it will be necessary to clean any rust from the exterior part of the shift lever before it i

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Poly Bed 4 X 2 Drive System 369.51. A 28mm circlip holds the 55-tooth forward gear to the reduction shaft. If either component shows wear or damage,

Poly Bed 4 X 2 Drive System 379.56. Clean and inspect the differential assembly. See Figure 9.56.• The ring gear teeth should not show wear or dama

Poly Bed 4 X 2 Drive System 38 Table 2: Transaxle TorqueNote 1: Apply releasable thread-locking compound such as Loctite 242.Note 2: The cable a

Poly Bed 4 X 2 Brake System 39ABOUT THIS SECTION:This section covers brake service and adjustments on the “poly bed” Utility Vehicle 4 X 2 Model 414 (

Poly Bed 4 X 2 Brake System 401.5. Any significant wear, damage, or binding should be addressed prior to making an operational test.NOTE: the operatio

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 lif

Poly Bed 4 X 2 Brake System 422.12. To remove the brake shoes: pivot the shoes away from the backing plate. This will reduce the spring tension. 2.1

Poly Bed 4 X 2 Brake System 432.18. Confirm that the shoes and springs are properly seated. See Figure 2.18. 2.19. Inspect the brake drums: See Figure

Poly Bed 4 X 2 Brake System 443.2. Adjust the nut and jam nut on the bolt that joins the clevis (pinned to the brake pedal arm) to the pivot pin that

Poly Bed 4 X 2 Brake System 453.11. Confirm that the parking brake light illuminates on the instrument panel when the parking brake is applied, and go

Poly Bed 4 X 2 Drive System 1ABOUT THIS SECTION:This section covers the drive system and transaxle used in the Big Country utility vehicle model serie

Poly Bed 4 X 2 Brake System 46www.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

4 X 2 Drive System - (Steel Bed) 47ABOUT THIS SECTION:This section covers the drive system and transaxle used in the Big Country utility vehicle model

4 X 2 Drive System - (Steel Bed) 482.10. A blocked vent can provoke oil leaks. The vent is located at the top of the transaxle housing. See Figure 2.1

4 X 2 Drive System - (Steel Bed) 493.6. An extremely bad axle bearing can mimic a dragging brake. If the axle shaft does not run concentric to the axl

4 X 2 Drive System - (Steel Bed) 504.6. Start the engine and check idle speed. The engine should idle at 1,400 RPM + 150. Correct the idle speed if it

4 X 2 Drive System - (Steel Bed) 514.13. At around 1,400 RPM the sheaves of the driving pulley should begin to close on the belt. See Figure

4 X 2 Drive System - (Steel Bed) 524.16. The ratio change should be fully accomplished by 3,000 RPM. Beyond this speed, increases in vehicle speed ar

4 X 2 Drive System - (Steel Bed) 535.5. Key points to inspect on the driven pulley are the ramp surfaces on the cams, and the polymer buttons that rid

4 X 2 Drive System - (Steel Bed) 546.4. Remove the drive belt.6.5. After the center bolt is loosened, remove the three screws that hold the cover onto

4 X 2 Drive System - (Steel Bed) 557. TRANSAXLE REMOVAL AND REPLACE-MENTThe transaxle is carried on the engine/transaxle cradle, and the entire cradle

Poly Bed 4 X 2 Drive System 22.9. A blocked vent can provoke oil leaks. The vent is located at the top of the transaxle housing. See Figure 2.9.2

4 X 2 Drive System - (Steel Bed) 567.12. Carefully roll the drive belt off of the driven pulley on the transaxle. See Figure 7.12.7.13. Match-mark the

4 X 2 Drive System - (Steel Bed) 577.21. Lift up on the bracket to remove it from the tran-saxle, complete with the actuator and the vac-uum reservoir

4 X 2 Drive System - (Steel Bed) 587.29. Remove the bolt that connects the front of the transaxle housing to the torque bracket on the engine/transaxl

4 X 2 Drive System - (Steel Bed) 598. TRANSAXLE INSTALLATION NOTES:8.1. Reverse the removal procedure to install the transaxle. The following items ar

4 X 2 Drive System - (Steel Bed) 609. LINK ASSEMBLY9.1. The link assembly (aka:dogbone joint) connects the engine and transaxle cradle to the frame of

4 X 2 Drive System - (Steel Bed) 6110. TRANSAXLE ORIENTATION10.1. The transaxle is a Dana / Spicer model H12 FNR. Before disassembly, become familiar

4 X 2 Drive System - (Steel Bed) 6210.9. The F-N-R shift shaft is located on the front sur-face of the housing. A 5/16” wrench spans the flats of the

4 X 2 Drive System - (Steel Bed) 6311.4. Remove the detent set screw using a straight-blade screwdriver. Retrieve the detent ball and spring from the

4 X 2 Drive System - (Steel Bed) 6412. TRANSAXLE DISASSEMBLY: GEAR SET REMOVAL AND DISASSEMBLY12.1. Carefully lift the differential

4 X 2 Drive System - (Steel Bed) 6512.6. Lift the reverse gear off of the intermediate shaft. See Figure 12.6. NOTE: The reverse gear has smaller O

Poly Bed 4 X 2 Drive System 33. DIAGNOSIS: CONFIRMING TRANSAXLE FAULT 3.1. Get as much information as possible from the customer regarding symptoms an

4 X 2 Drive System - (Steel Bed) 6612.11. Push the shift actuator into the case, and remove it. See Figure 12.11.12.12.Remove the seals from the case.

4 X 2 Drive System - (Steel Bed) 6712.16.Careful application of a propane torch (NOT oxy-accetelene), or heating the housing in an oven for about ten

4 X 2 Drive System - (Steel Bed) 6813. TRANSAXLE DISASSEMBLY: DIFFERENTIAL13.1. Position the differential assembly so that it rests on the differentia

4 X 2 Drive System - (Steel Bed) 6913.7. If it is necessary to remove the bearing, use a bearing puller. See Figure 13.7. 13.8. Position the different

4 X 2 Drive System - (Steel Bed) 7013.13.If it is necessary to remove the bearing, use a bearing puller. See Figure 13.13.14. TRANSAXLE: AXLE TUBES14.

4 X 2 Drive System - (Steel Bed) 7114.4. Remove the brake shoes:• Release the small blue tension spring adjacent to the brake adjuster.• Remove the br

4 X 2 Drive System - (Steel Bed) 7214.10. Drill a small (1/8” or less) pilot hole into the out-side edge of the retaining ring. Drill most of the way

4 X 2 Drive System - (Steel Bed) 7314.16.Clean the axle, apply a small amount of motor oil or wheel bearing grease to the surface that the axle bearin

4 X 2 Drive System - (Steel Bed) 7415. IN CRADLE ENGINE SERVICENOTE: Basic maintenance, valve adjustment, and fuel system repair can be easily accom-p

4 X 2 Drive System - (Steel Bed) 7515.6. Remove the three screws securing the grid screen to the grid screen holder using a 10 mm wrench. Remove the

Poly Bed 4 X 2 Drive System 44.5. There is a black plastic cover on the gearshift control. Slide it rearward, then lift it away from the gear shift c

4 X 2 Drive System - (Steel Bed) 7615.11. The fuel pump can be tested on the bench using a hand operated vacuum pump to confirm the initial tests. See

4 X 2 Drive System - (Steel Bed) 7715.18.Rotate the engine crankshaft manually to locate top dead center (TDC) on the compression stroke for cylinder

4 X 2 Drive System - (Steel Bed) 7815.23.Adjust the clearance on cylinder # 2.15.24.Install the valve cover. See Figure 15.24.15.25.Install both spark

Poly Bed 4 X 2 Drive System 54.12. Within the housing for the shifter control there is a torsion spring that returns the shift lever to the center of