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Dixon Z-Drive Transaxle Disassembly

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Dixon Illustrated Parts Diagrams

Drive Cone Replacement
Estimated Time Required: 45 minutes

Tools Required:
(1) 15/16" socket
(1) ratchet, breaker bar or air wrench
(1) 15/16" combination wrench
(1) Torque wrench calibrated in ft/lbs
(1) bearing puller or hammer and punch
(1) Loctite Anti-Seize

Disassembly of the Drive Cone Unit


Figure 40

(1) Cone Shaft Lock Nut PN 3388 superceded to PN 539115670
(2) Cone Drive Shaft PN 5320 superceded to 539116022
(3) Upper Drive Cone PN 5109 superceded to 539115957
(4) Long Keys PN 5070 superceded to 539115950
(5) Upper Bearing PN 5343 superceded to 539116040
(6) Long Spacer PN 5316 superceded to 539116018
(7) Lower Drive Cone PN 5109 superceded to 539115957
(8) Middle Spacer PN 5317 superceded to 539116019
(9) Lower Bearing PN 5343 superceded to 539116040
(10) Short Spacer PN 2164 superceded to 539115329
(11) Drive Pulley PN 5326 superceded to 539116027
(12) Short Key PN 3385 superceded to 539115667
     


Figure 41

1. Using a 15/16" socket, remove the top nut from the drive cones assembly.  If air tools are not available, the bottom of the shaft can be held in place using a 15/16" open end wrench.  (This allows the drive pulley to remain attached to the shaft.)
     
  NOTE: If the bottom nut releases first, reverse the shaft during reassembly, as both ends of the shaft are identical.
     
  NOTE: The cone shaft should slide out of lower cone, bearing and cone frame, however, tapping the shaft through the upper cone may be necessary if the cone has seized to the shaft.  If the cones cannot be removed by use of penetrating oil and tapping the shaft, it will be necessary to cut the shaft in order to remove and replace it.
     


Figure 42

2. Remove the upper and lower bearings from the cone frame.
     
  NOTE: If the bearings do not slip out easily, they may be removed by use of a bearing driver or hammer and punch.
     
3. Inspect the bearings for wear.  Inspect the spacers for burrs, wear or cracks.
     
  Note: The bearings are identical and may be reversed without harm.
     
4. Inspect the drive cones for uneven wear, rough spots, glazing or any other signs of wear or damage.  See the troubleshooting guide for examples of normal and abnormal wear.
     
5. Inspect the keys, key ways and shaft for burring or signs of wear or damage.
     
6. Replace worn, damaged or defective parts as needed.
     

Re-Assembly of the Drive Cone Unit

     


Figure 33

1. Insert/press both upper and lower bearings into the frame.
     
  NOTE: The bearings may require a press fit into the frame.  This can be accomplished with a press, hammer and drift or the use of chilled bearings into a warm frame.  Do not use any lubrication.
     


Figure 44

2. Coat the cone shaft with Loctite Anti-Seize
     
  NOTE: Ensure that the anti-seize is sprayed on the shaft only.  Anti-seize will (ruin/destroy/etc) the drive cones and discups if it is sprayed onto the drive surfaces or any part that comes into contact with the drive surfaces.
     


Figure 45

3. Install the drive pulley and short key (PN 5070 superceded to 539115950) onto the cone shaft.
     


Figure 46

4. Reassemble the drive cone assembly by sliding the small black spacer onto the shaft and then inserting the shaft through the lower bearing in the bottom of the cone frame.
     


Figure 47

5. Slide the middle sized, zinc coated spacer onto the cone shaft.
     


Figure 48

6. Slide the lower drive cone, tapered end down, on the cone shaft.  Align the key ways and insert the key.
     


Figure 49

7. Slide the large zinc coated spacer onto the cone shaft.
     


Figure 50

8. Install the upper cone and key.
     


Figure 51

9. While holding the bottom nut with a 15/16" wrench, tighten the top nut to a torque valve of 75 ft/lbs.