Rear PTO Kit

Important: Use the instructions in steps 1 through 15 when installing the kit on a vehicle with a serial number greater than 240000001; otherwise skip to Connecting the PTO Cable.

1. Unscrew and remove all of the knobs from the console levers and from the gear shift lever (Figure 5).

   

   Figure 5

   1. Console levers
   2. Gear-shift lever

2. Remove the 6 screws that secure outside edge of the center console cover plate to the frame and remove the cover plate (Figure 6).

   

   Figure 6

   1. Console cover plate
   2. Reservoir hose
   3. Seat
   4. Shroud

3. Disconnect the reservoir hose from the radiator and plug or clamp the hose to retain the coolant (Figure 6).

4. Remove the 8 capscrews securing the seats and shroud to the mounting brackets (Figure 6). Remove seats and shroud.

5. Remove the cotter pins and clevis pins that secure the cables to the console levers (Differential Lock, Hi–Low and Hydraulic Lift). Retain cotter pins and clevis pins.

   Note: Retain the cotter pins and clevis pins.

6. Remove the nut and bolt securing the console levers to lever the support bracket (Figure 7) and the remove console lever assembly from the lever-support bracket.

   

   Figure 7

   1. Nut
   2. Bolt
   3. Lever-support bracket
   4. Spacer

7. Remove the spacer (Figure 7) from the assembly and install the new PTO lever in its place on the pivot tube.

   Note: Position the lever as shown in Figure 8.

   

   Figure 8

   1. PTO lever
   2. Flat washer
   3. Wave washer
   4. Pivot tube
   5. Spacer

8. Install the previously removed components onto bolt, positioning each as shown in Figure 8.

9. Secure the bolt to the lever support bracket with the nut that you removed previously (Figure 8).

1. Route the PTO cable under the rear of the lever support bracket.

2. Connect the PTO cable clevis to the hole in PTO lever with a clevis pin and a cotter pin (Figure 9).

   

   Figure 9

   1. PTO lever
   2. PTO cable clevis
   3. Clevis pin
   4. Cotter pin

3. Secure the PTO cable to underside of the lever support bracket with a clamp and 2 hex-socket head self-tapping screws (Figure 10).

   Note: The PTO lever should be positioned so it is in line with the Hi–Low lever (Engaged position) when the transaxle is shifted into the Low position.

   

   Figure 10

   1. PTO cable
   2. Lever support bracket
   3. Clamp

4. Route the cable, along the existing cables, and to the cable bracket mounted at front left corner of the transaxle (Figure 11).

   

   Figure 11

   1. PTO Cable
   2. Cable bracket
   3. Jam nut

5. Loosen the rear jam nuts on the PTO cable and insert the end of cable into the opening in the bracket. Loosely secure the PTO cable to the bracket with the jam nuts.

6. Install the shroud, seats, console cover plate, and lever knobs onto the machine; refer to step 2 in Installing the PTO Controls.

   Note: When the PTO is engaged, the lever must not contact the center console plate.

Important: Accomplish the installation steps in Connecting the PTO Cable only when installing the kit on a machine with a serial number prior to 239999999; otherwise skip to Installing the PTO to the Transaxle.

Note: Some of the parts required to install this kit on machines with serial numbers prior to 239999999 are not included in the kit, but are listed in the parts catalog.

1. Remove all of the knobs from the center console levers (Figure 12).

   

   Figure 12

   1. Center console cover
   2. PTO lever (shown installed)

2. Remove the 6 screws that secure the outside edge of center console cover plate to the frame and remove cover plate (Figure 12).

3. Connect the PTO cable clevis to the bottom hole in PTO lever with a clevis pin and cotter pin (Figure 13)

   

   Figure 13

   1. PTO lever
   2. PTO cable
   3. Clamp
   4. PTO lever support
   5. Self-tapping screws

4. Secure the PTO cable to the PTO lever support with a clamp and 2 self tapping screws (Figure 13).

5. Insert the other end of the PTO lever cable through the opening in right side of the console and through the cable holder in the rear of the console (Figure 14).

   Note: Route the cable, along the existing cables to the cable bracket mounted at the front left corner of the transaxle.

   

   Figure 14

   1. PTO cable
   2. Cable bracket
   3. Jam nut

6. Loosen the rear jam nuts on cable and insert the end of cable into the opening in the bracket. Loosely secure the PTO cable to the bracket with the jam nuts.

7. Using the 3 self tapping screws supplied in the kit, mount the PTO lever support to the right side of console.

   Note: The lever location is shown in Figure 8.

8. Clean console plate and install the operation decal to the console next to PTO lever, locating the decal as shown in Figure 15.

   

   Figure 15

   1. Console
   2. Operation decal

9. Install the console cover plate and the lever knobs to machine.

   Note: When the PTO is engaged, the lever must not contact the center console plate.

Note: The remaining steps pertain to installing the kit on all vehicles unless otherwise specified.

1. Disconnect the hydraulic hose from the fitting on transaxle cover plate (Figure 16).

   Note: Cap the hose end to prevent contaminants from entering the hose.

   

   Figure 16

   1. Transaxle cover plate
   2. Hydraulic hose
   3. Fitting

2. Remove the fitting from cover plate.

3. Install the small O-ring onto the fitting as shown in Figure 17.

   

   Figure 17

   1. Fitting
   2. Small O-ring

4. Install the fitting into the front of the new PTO and position the fitting as shown in Figure 18.

   

   Figure 18

   1. PTO
   2. Fitting

5. Remove the 5 bolts, lock washers, and nut that secure the cover plate to the transaxle and carefully remove the cover plate to prevent damage to the O-ring seal (Figure 18).

   Note: Retain the fasteners for installation later.

1. Install the 2 alignment pins into the holes in the transaxle, at locations shown in Figure 19.

2. Use the large O-ring, mounting bolts, lock washers, and nut that you removed from the transaxle cover plate mount the PTO assembly onto the transaxle (Figure 19).

   Note: When mounting the PTO assembly, make sure that the large O-ring is positioned properly in the transaxle groove to prevent damage. Do not reuse an old O-ring.

   

   Figure 19

   1. PTO
   2. Alignment pins
   3. Large O-ring

3. Remove the cap from the disconnected hydraulic hose and install the hose to the PTO fitting with the previously removed clamp.

   Note: Make sure the hose and fitting are clean before you connect them.

4. Move the PTO lever at the center console all the way back (towards the rear of the console) and move the PTO lever arm (Figure 20) on the transaxle to the right side (passenger side).

   

   Figure 20

   1. PTO lever arm
   2. Cable clevis
   3. PTO switch connector

5. Adjust the cable clevis, jam nuts, or both clevis and nuts (which secure the cable to the bracket) until the clevis pin drops freely through the aligned mounting holes in the clevis and lever arm (Figure 20).

6. Secure the clevis pin with the cotter pin and tighten jam nut that secures the cable to the cable clevis, then tighten the jam nuts that secure the cable to the bracket.

7. Remove the jumper cable from the wire harness located in front of the PTO.

8. Route the wire harness under the positive battery cable and connect the wire—harness connector into the PTO switch connector.

9. Mount the PTO shield to the rear frame tube with 4 capscrews, 2 spacers, and 4 locknuts (Figure 21).

   

   Figure 21

   1. PTO shield

10. Apply the warning decal to the lower-rear cross tube next to the existing decal, just above hitch point (Figure 22).

    

    Figure 22

    1. Rear cross tube
    2. Warning decal

11. Use the 5 cable ties supplied in the kit to secure the PTO cable to the existing wiring harness.