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Dixon Z-Drive Transaxle Disassembly

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Transaxle Bench Adjustments
Estimated Time Required: 50 minutes

Tools Required:
(1) 7/16" combination wrench
(1) 9/16" combination wrench
(1) 11/16" wrench
(2) 3/4" combination wrench
(1) 7/32" allen wrench
(1) adjustment gauge (PN 539116707 and PN 539115692 if early 1999 - present)
(1) .050" feeler gauge


Figure 73

1.   Rubber spring assembly gap adjustment (1995 - early 1999)
1A. Rubber spring assembly gap adjustment (early 1999 - present)
2.   Neutral spring assembly gap adjustment
3.   90 degree gauge for cradle height adjustment
4.   Mounting hole for cradle height adjustment
5.   90 degree gauge for roller plate adjustment
     

Roller and roller plate adjustment and discup alignment

     


Figure 74

1. Using a 9/16" combination wrench, remove the top neutral springs.
     

2. Using a 9/16" combination wrench, back off the bottom neutral springs completely.
     


Figure 76

3. Using a 7/16" combination wrench, loosen the lock nut on top of each rubber spring assembly.
     


Figure 77

4. Using two 3/4" combination wrenches, loosen the jam nuts on top of each rubber spring assembly.
     


Figure 78

5. Slide the rubber spring assemblies off the rear of the cradles.
     


Figure 79

6. Using the alignment gauge, check both roller plates to ensure that they are perpendicular to the base.  Adjustment is made by using a 9/16" wrench to loosen or tighten the attachment nuts on the top and bottom of each roller plate.
     


Figure 80 Discup not aligned


Figure 81 Procedure for alignment


Figure 82 Discup aligned

7. Using the alignment gauge, check the discups to ensure that they are perpendicular to the back edge of the center section.  Adjustment is made by using a 7/32" allen wrench to turn the pivot bolt.
     


Figure 83

8. Bolt the alignment gauge to the front of the cradle, where double ball joint screws into the casting.  The short leg of the alignment gauge should rest on the base plate.

NOTE: This ensures that the next step is completed in the correct neutral position.

     


Figure 84

9. Grasp the front of both cradle assemblies and pull inward in order to check the gap between the rollers and roller plate.  The correct gap is .050".  If the gap is too tight, loosen the pivot bolt and top and bottom attachment nuts on the roller plates.  Turn each nut one flat in ratio of 1:1:1.  If the gap is too loose, tighten the attachment nuts and pivot bolt in the same manner.

Repeat this procedure on the opposite cradle.
     


Figure 85

10. Remove the height gauge from the front of the cradle.
     
11. When the gap is set correctly, use an 11/16" combination wrench to tighten both the inner and outer jam nuts on the pivot bolts while holding the pivot bolt in place with 7/32" allen wrench.
     
At this point:
-  The roller plates should be perpendicular to the base.
-  The discups should be perpendicular to the back of the center section casting
-  The gap setting between the rollers and roller plates should be .050" with the discups held against the cones.
     

Rubber Spring Assembly and Pre-Load Adjustment

     


Figure 86

1. Push the rubber spring assemblies back into the fork at the rear of the cradle castings.  The rod end must be perpendicular to the L-Rod, and the rubber spring assemblies must run parallel to the rear of the center section.
     


Figure 87

2. Turn the rubber spring mount tube clockwise until the lower rubber spring is held tightly against the bottom of the cradle.
     


Figure 88

3. Set the rubber spring pre-load by tightening the lower jam nut against the upper rubber spring.  Hold the bottom of the rubber spring mount tube to keep it from turning.  Tighten the lower jam nut until the pre-load gauge sandwiches the washers outside the rubber springs.
     
  NOTE: On transaxles build after June 1999, it is necessary to use the gauge shown at position 1A, page 38, to set the correct pre-load.
     


Figure 89

4. Once the proper pre-load has been set, lock the 3/4" jam nuts together on the rubber spring mount tube.
     

Centering the Discups on the Cones

     


Figure 90

1. Place the cradle height gauge at the front of the cradle where the double ball joints screw into the casting.

The cradle should sit lower at the front.  If the cradle casting sits higher than the bolt hole in the height gauge, repeat steps 2 through 4 of the Rubber Spring Assembly and Pre-Load Adjustment Instructions.
     


Figure 91

2. Turn the two jam nuts on the top of the rubber spring assembly clockwise until a bolt installed through the hole in the height gauge can be screwed into the cradle casting.  The bottom edge of the gauge must be setting flat on the transmission base plate.

Repeat this procedure on the opposite cradle.
     
3. Turn the drive cones slowly.  As the cones turn, slowly tighten or loosen the jam nuts on the top of the rubber spring assembly until the cones turn free with no contact with the discups.
     
4. Remove the alignment gauge from the cradle.
     
Bench Neutral Adjustment
     


Figure 92

1. Bring the lower neutral spring up the neutral rod until the neutral gauge can be slid between the jam nut on the neutral rod and the adjusting nut on the bottom of the spring.
     

Figure 93
2. Insure that the neutral stud is centered from side to side in the hole in the cradle casting.

NOTE: If the stud is off center it should be straightened or replaced
     


Figure 94

3. Install the top neutral spring parts and:
  • Tighten the top adjustment nut until the discup just comes free from the cone
  • Note the position of the nut
  • Counting the number of revolutions, continue to turn the nut clockwise until the discup drags again
  • Turn the nut counterclockwise one half of the counted revolutions
     


Figure 95

4. Tighten the 7/16" lock nuts to lock the rubber spring assemblies in place

Note:  When the transaxle is replaced into the chassis and the drive levers are connected, a small amount of fine tuning on the neutral springs will be required
     


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