Cub Cadet Big Country - Steel Bed User Manual
Service Manual
NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power
equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.
These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced
individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all instructions
and common sense when working on power equipment. This includes the contents of the product’s Operators Manual, supplied
with the equipment. No liability can be accepted for any inaccuracies or omission in this publication, although care has been
taken to make it as complete and accurate as possible at the time of publication. However, due to the variety of outdoor power
equipment and continuing product changes that occur over time, updates will be made to these instructions from time to time.
Therefore, it may be necessary to obtain the latest materials before servicing or repairing a product. The company reserves the
right to make changes at any time to this publication without prior notice and without incurring an obligation to make such
changes to previously published versions. Instructions, photographs and illustrations used in this publication are for reference
use only and may not depict actual model and component parts. © Copyright 2005 MTD Products Inc. All Rights Reserved
MTD Products LLC - Product Training and Education Department
Cub Cadet Big Country 4x2
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
This Service Manual is not a substitute for the Operator’s Manual. You must read, understand
and follow all of the directions in this manual as well as the Operator’s Manual before working
on this power equipment.
PRINTED IN USA
CUB CADET LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
FORM NO.769-00965
(11/2003)
TABLE OF CONTENTS
Brakes...............................................................................................................1
Visual Inspection...............................................................................................1
Operational Tests..............................................................................................2
Complete Inspection..........................................................................................3
Brake Adjustment..............................................................................................7
Brake Linkage Adjustment ................................................................................9
4x2 Drive – Dana Transaxle.............................................................................. 13
Engine/Transmission Cradle............................................................................. 13
“Dogbone” Link Assembly................................................................................. 13
Transaxle Maintenance.....................................................................................13
Transaxle Removal ...........................................................................................14
4x2 Pushbutton Gear Selector..........................................................................15
Description........................................................................................................15
Self Diagnostics.................................................................................................18
Terms and Definitions ....................................................................................... 19
Gear Selector System Diagnostics.................................................................... 20
Explanation of Methodology..............................................................................20
Basic Checks ....................................................................................................20
Vacuum Tests ................................................................................................... 23
Differential Lock Actuator.................................................................................. 27
Gear Selector Electrical System........................................................................28
Differential Lock.................................................................................................31
Big Country 4 x 2
IMPORTANCE:
It is important that the brakes of the Big Country 4 X 2
Utility Vehicle be properly maintained in order for the
utility vehicle to operate safely and dependably. In
addition to the obvious safety concerns, there is an
electric interlock between the brakes and the gear
selector mechanism. If the brakes are out of adjustment, the gear selector mechanism will not work as it
was designed to. The condition and adjustment of the
brake system should be checked in accordance with
the two-tiered service interval described under the
“Service Intervals” heading in “Description of the Brake
System”.
DESCRIPTION OF THE BRAKE SYSTEM:
• The brake pedal arm lifts up on the pull bolt that
transfers the force through a stack of bellville
washers to an equalizer bracket. The equalizer
bracket distributes the brake pedal force
between the cores of two cables. The bellville
washers are stacked in opposite directions to
provide a spring action, softening the brake
pedal feel.
• Each cable housing is mounted to a bracket on
the firewall using two large jam nuts. Each cable
actuates a drum brake at the end of each rear
axle.
•A parking brake latches the brake pedal in the
applied position when engaged.
• There are two electrical switches in the system. A parking brake switch lights an indicator
bulb in the instrument panel to help prevent the
operator from trying to drive the Big Country 4 X
2 with the brakes engaged. A brake switch
works with the Electronic Shift Module to prevent
the operator from shifting gears without the
brake applied.
• Service intervals will vary with the type severity
of use. If the vehicle is operated on hills or with
heavy loads, it may be necessary to shorten the
maintenance intervals because of the increased
load on the brake system and the increased consequences of brake system failure. A visual
inspection and operational test should be performed every 50 hours. The brake drums
should be removed for a complete inspection
every 500 hours or 24 months, as the transaxle gear lube is being changed.
1. VISUAL INSPECTION AND OPERATIONAL TEST:
1.1. Open the hood of the Big country 4 X 2 and
examine the brake arm, parking brake latch, and
all of the associated hardware.
1.2. Check the condition of the brake cables and
their mounting hardware: See Figure 1.2.
Left brake
cable
Cable
clamp
Fuel tank
Figure 1.2
• Jam nuts at the front should be secure.
• Locating clamps at the front of the engine com-
partment should be secure.
• Mounting clips and clevis pins at the back end of
the cable housing should be secure and in good
condition.
• Cable cores should not be frayed or corroded.
Rubber boots should be intact.
• Cable housings should not be kinked, chafed,
burned, crushed or otherwise damaged.
1.3. Any significant wear, damage, or binding should
be addressed prior to making an operational
test.
1
Big Country 4 x 2
1.4. If the operator of the vehicle has any specific
brake performance complaints, these complaints
should direct the visual examination and be confirmed during the operational test. If the operator describes an inherently unsafe condition, a
complete inspection should be performed in lieu
of the operational test.
2. OPERATIONAL TESTS
2.1. Operational be performed in a safe location that
is free of traffic, obstacles and hazards.
See Figure 2.1.
2.7. The parking brake should hold the vehicle
securely on a 22 degree incline with an operator
and a capacity load (800lbs.) in the bed. It
should take less than 100 pounds of pedal pressure to push the pedal down far enough to
engage the parking brake. See Figure 2.7.
Figure 2.7
Figure 2.1
2.2. Check the following points of performance:
2.3. The brakes should not drag when they are not
applied.
2.4. The gear selector buttons should operate when
there is enough pressure on the brake pedal to
prevent vehicle motion.
2.5. When the brakes are applied at speed, there
should be no unusual noises, and no pedal pulsation.
2.6. When the brakes are applied at speed on a lowcoefficient surface (such as a gravel parking lot)
the brakes should lock both rear wheels at the
same time.
2.8. There should be 7/8” of pedal travel as measured at the edge of the brake pedal pad before
pressure on the pedal begins to build.
See Figure 2.8.
.875” free-play
from here...........to here
Figure 2.8
2.9. If the Big Country 4 X 2 does not perform as
described, adjust the brakes as described in the
“Brake Adjustment” section of this manual.
2.10. If adjustment does not completely fix the problem, follow the procedures described in the
“Complete Inspection” section of this manual,
and repair any mechanical faults encountered.
2
Big Country 4 x 2
3. COMPLETE INSPECTION (DRUM AND SHOE REMOVAL)
3.1. Perform operational tests if no unsafe conditions
have been described by the operator.
NOTE: All brake repair work should be done in
compliance with applicable OHSHA and EPA
regulations.
3.2. Loosen the five lug nuts on each rear wheel 1/2
turn each using a 3/4” socket.
3.3. Raise and safely support the rear of the Big
Country 4 X 2 with jack stands. See Figure 3.3.
Safe jack
location
3.5. Engage the parking brake. Insure the parking
brake assembly is engaging and disengaging
properly. The latch (parking brake lever) should
hook securely over the tab on the brake pedal
arm. See Figure 3.5.
Tab
Parking
brake lever
Brake
pedal arm
Figure 3.5
3.6. Attempt to rotate the rear wheels (drive wheels)
by hand. Neither wheel should rotate.
Figure 3.3
3.4. With the parking brake disengaged, attempt to
rotate the rear wheels. They should not drag. If
one or both rear wheels are difficult to rotate,
check the adjustment as described in the “Brake
Adjustment “ section of this manual.
3.7. If either wheel rotates: release the parking brake
and check the adjustment as described in the
“Brake Adjustment “ section of this manual.
3.8. Open or remove the hood. See Figure 3.8.
Slide to remove
Figure 3.8
NOTE: With some front mounted accessories in
place, it may be easier to open the hood far
enough to remove the hairpin clip from the hood
mounting pin, slide the hood assembly to the
right, and remove it completely
3
Big Country 4 x 2
s
3.9. Inspect the brake cables for any damage or
wear. Inspect the hardware securing the cables
to the brake pedal assembly.
See Figure 3.9.
Equalizer bar
Brake cables
Bellville washer
Jam nuts
Figure 3.9
3.10. Release the parking brake.
3.11. Inspect the brake cables at the rear drive
wheels. Inspect the clevis pin, cotter pin, E-clip,
cotter pin, and washer securing the the brake
cables and the brake actuator hardware. See
3.11..
E-clip
Cable
Jam nut
Clevis pin
Mounting bolts
Brake actuator
3.15. Slacken the brake adjuster using a brake
adjuster spoon or flat blade screw driver.
See Figure 3.15.
Star
wheel
Brake
adjuster
Figure 3.15
NOTE: The brake adjuster is the same on both
sides of the Big Country, but is installed in opposite directions. The adjuster is installed with the
star wheel toward the front of the left side brake
assembly. The adjuster is installed with the star
wheel towards the rear of the right side brake
assembly. There is a conventional right hand
thread on the shaft attached to the star wheel.
Walk the teeth of either star wheel down in
order to loosen the brake shoe adjustment.
Walk the teeth up in order to tighten the
adjustment.
3.16. Inspect the brake shoes and drum for wear. The
shoes should be free of oil. See Figure 3.16.
Brake
shoes
Window in
brake drum
Brake actuator
extension arm
Cotter pin
Figure 3.11
3.12. Remove the rear wheels.
3.13. Remove the brake drums. If the brake drum will
not slide easily over the brake shoes, perform
the following two steps.
3.14. Rotate the brake drum until the access hole
(closest to the outer edge of the hub) is at the 6
O’clock position.
Brake
drum
Figure 3.16
4
NOTE: If the friction material is contaminated
with oil, identify the source, repair the leak, and
replace the shoes.
NOTE: The friction material on the brake
shoes should not be worn to a thickness of less
than 3/32”. The friction material should not be
contaminated with oil. The friction material
should not show any signs of separating from
the steel portion of the brake shoe. If any of
these conditions exist, replace the brake shoes.
NOTE: If drums are reused at the time of reline,
they should be turned if the depth of scoring
exceeds .010"; if the inside diameter at the open
end of the drum exceeds the inside diameter at
the closed end by more than .010: (bellmouth
condition); if the drum rubbing surface is concave or convex by more than .005"; if they are
heat checked; and if they are out of round by
more than .010 total indicator reading or if pedal
pulsations or brake roughness is noticed. The
rebore limit is .060" over the original maximum
drum diameter of 7.005". If reboring to .060”
maximum does not correct any of these conditions, then the drum should be replaced. New
drums have a #50 grit blast applied to the rubbing surface. Drum surface finish is 40-125
micro-inches friction surface of the drum should
be smooth and true within .003 “.
3.17. Remove the cotter pins and clevis pins securing
the brake cables to the actuators on each brake.
The brake pedal may be carefully depressed
while the cable is disconnected from the actuator. This will confirm that the cable and linkage
move without binding. See Figure 3.17.
Big Country 4 x 2
3.18. Remove the “R” shaped clips securing the brake
actuator to the brake shoes. See Figure 3.18.
“R” Shaped clips
Figure 3.18
3.19. Remove the brake actuator.
NOTE: The clevis pin is installed in the hole furthest from the pivot pin. The head of the pivot is
facing. The Pivot pin is secured to the actuator
by a C-clip and wave washer.
3.20. Inspect the actuator for any binding at the pivot
pin. See Figure 3.20.
Check for binding
and wear
Clevis
Brake Actuator
Figure 3.20
3.21. Rotate the star wheel on the adjuster to shorten
the adjuster to the end of its travel.
Figure 3.17
5
Big Country 4 x 2
3.22. Pry out on the base of the brake shoes while
removing the adjuster. See Figure 3.22.
Blue
extension
spring
Brake adjuster
Figure 3.22
3.23. Remove the blue extension spring from the base
of each brake shoe. The extension spring keeps
the adjuster in contact with the base of the brake
shoe. See Figure 3.23.
Brake Shoe
3.24. Remove the torsion springs. See Figure 3.24.
Torsion
Spring
Release from bottom lip
using a screwdriver
or brake spoon
Figure 3.24
NOTE: Relieve the tension from the torsion
spring by prying up on the bottom of the spring
until it separates from the ledge on the brake
shoe.
NOTE: There is one blue and one yellow torsion
spring on each brake assembly. The blue
spring is installed towards the front on the
right side brake assembly and towards the
rear on the left side brake assembly.
Blue
extension
spring
3.25. Slide the brake shoes out from behind the cast
ears that hold them in place, and remove them.
See Figure 3.25.
Brake Shoe and
Spring Orientation
Cotter pin tool
Figure 3.23
Figure 3.25
3.26. Replace any damaged, worn, or corroded parts.
6
Big Country 4 x 2
3.27. Assemble the brakes by reversing the shoe
removal process. See Figure 3.27.
Dust cover
Brake
mounting plate
Figure 3.27
NOTE: Apply a small amount of white lithium
grease to the metal-to-metal contact points as
the brake is assembled.
NOTE: Measure the bore of each drum, then set
the adjuster to bring the brake shoes for that
drum out to slightly less than the I.D. of the
drum. If a brake shoe and drum caliper is not
available, a tape measure will usually provide a
measurement that is close enough.
3.29. Adjust the brakes as described in the “Brake
Adjustment” section of this manual.
3.30. After brake adjustment is complete, perform the
operational test as described in the “Visual
Inspection and Operational Test” section of this
manual.
4. BRAKE ADJUSTMENT
4.1. If the brake adjustment is being performed after
other brake service, such as brake shoe
replacement or brake cable replacement, begin
with the “Brake Shoe Adjustment” step. Continue with the “Brake Linkage Adjustment”.
4.2. If brake adjustment is being performed as part of
scheduled maintenance or because of a performance complaint, begin by performing the
steps of the “Complete Inspection” section of this
manual up through the point of brake drum
removal, then proceed from the “Brake Shoe
Adjustment” step. Continue with “Brake Linkage
Adjustment”.
BRAKE SHOE ADJUSTMENT:
4.3. With the brake drums removed, make a visual
inspection of the brake shoes and the components that actuate them. See Figure 4.3.
3.28. Install the brake drum without the wheel using
two of the five lug nuts. Install the lug nuts
inside-out, so that the flat side is against the
brake drum. See Figure 3.28.
Lug nuts
Figure 3.28
NOTE: Rotate the brake drum as the lug nuts
are tightened to insure that it is centered.
Figure 4.3
7
Big Country 4 x 2
4.4. Disconnect the clevis on the end of each brake
cable from the brake actuator extension arm by
removing the cotter pin and clevis pin.
See Figure 4.4.
Figure 4.4
NOTE: This step isolates the brake form the link-
age that actuates it, so that the two portions of
the system do not interfere with each other.
4.7. Set the adjuster so there is slight drag on the
brake drum when turned by hand. Then adjust
until no drag is present. At this point, play
should be absent from the actuator.
See Figure 4.7.
Loosen Tighten
Star Wheel
Figure 4.7
4.8. Repeat the process for the second brake, and
proceed with the brake linkage adjustment.
4.5. Install the brake drum using two of the five lug
nuts. Install the lug nuts inside-out, so that the
flat side of the nut faces the drum. Rotate the
drum during installation to center it.
See Figure 4.5.
Flat blade
screw driver
Figure 4.5
4.6. Position the access slot in the drum at the 6 oclock position, so that a brake adjuster spoon or
flat blade screwdriver can be inserted to reach
the star wheel on the brake adjuster.
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