Hydro-Gear T2 Installation and operating manual

We set the wheels in motion.®
T2™
Integrated Hydrostatic Transaxle
Service and Repair Manual
BLN-52749
November 2006

T2™ i
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Description and Operation . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .3
External Features . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . .6
Product Identification. . . . . . . . . . . . . . . . . . . . . . . . . .6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tool Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Servicing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . .9
External Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .9
Service and Maintenance Procedures . . . . . . . . . . . .9
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fluid Volume and Level . . . . . . . . . . . . . . . . . . . . . . . .9
Fluid Change Procedure . . . . . . . . . . . . . . . . . . . . . .10
Purging Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Return To Neutral Setting . . . . . . . . . . . . . . . . . . . . .12
Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .13
Friction Pack Adjustment. . . . . . . . . . . . . . . . . . . . . .13
Tear Down and Reassembly . . . . . . . . . . . . . . . . . . .14
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . .14
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . .14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Transaxle Removal . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fan and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Expansion Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Control Arm Assembly . . . . . . . . . . . . . . . . . . . . . . .19
Return to Neutral Option . . . . . . . . . . . . . . . . . . . . . .20
Brake Arm & Brake Assembly . . . . . . . . . . . . . . . . . .21
Side Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RH Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Bull Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Reduction Gear Set. . . . . . . . . . . . . . . . . . . . . . . . . .25
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Bypass Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Center Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Cylinder Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
LH Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Expansion Tank Hose and Fitting . . . . . . . . . . . . . . .32
Assembly after Teardown . . . . . . . . . . . . . . . . . . . . .33
Side Housing-Screw Sequence . . . . . . . . . . . . . . . .34
T2 Transaxle Exploded View . . . . . . . . . . . . . . . . . .35
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 37-38
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
TABLE OF CONTENTS

T2™ 1
FOREWORD
Headquartered in Sullivan, Illinois,
Hydro-Gear®is a world leader in the design,
manufacture, and service of quality hydrostatic
transaxles for the lawn and garden industry.
The mission of our company is to be recog-
nized by our customers and the industry as a
world-class supplier and the quality leader in
everything we do.
This Service and Repair Manual is designed
to provide information useful in servicing and
troubleshooting the Hydro-Gear T2™Inte-
grated Hydrostatic Transaxle.
Also included is a glossary of terms that are
frequently used throughout the industry and in
Hydro-Gear service publications. Understand-
ing terminology is very important!
It is necessary, and a good shop practice, that
your service area be equipped with the proper
tools and the mechanics be supplied the latest
information available. All repair procedures
illustrated in this guide are suggested, but pre-
ferred methods of repair.
Internal repair procedures require that the
transaxle unit be removed from the vehicle.
This is not a certification, test or study guide for
a certification test. If a technician is interested
in certification, they should contact an agent
representing the EETC (Equipment and Engine
Training Council) at [phone] or their
Hydro-Gear Central Service Distributor. Many
distributors will be hosting certification testing.
These study guides will cover most of the prod-
ucts and manufacturers in our industry.
For more information about Hydro-Gear or our
products, please contact your Central Service
Distributor, or call our Customer Service Depart-
ment at [phone].

2 T2™
The T2 has a self contained fluid supply and
an internal filter. The fluid is forced through
the filter by a positive “head” on the fluid in the
housing/expansion tank with an assist by the
negative pressure created in the pump pistons
as they operate.
The check valves in the center section are used
to control the makeup flow of the fluid to the low
pressure side of the loop.
A block lifting bypass is utilized in the T2 to
permit moving the vehicle for a short distance
at a maximum of 2 m.p.h. (3.2 Km/h) without
starting the engine. The T2 utilizes an in-line
floating disc brake controlled by a “cam” style
actuating arm.
INTRODUCTION
The purpose of this manual is to provide in-
formation useful in servicing the Hydro-Gear®
T2™Integrated Hydrostatic Transaxle. This
manual includes the T2’s general description,
hydraulic schematic, technical specifications,
servicing and troubleshooting procedures.
The transaxle normally will not require servic-
ing during the life of the vehicle in which it is
installed. Should other servicing be required,
the exterior of the transaxle will need to be
thoroughly cleaned before beginning most
procedures. Do not wash the transaxle while it
is hot. Do not use a pressure washer to clean
the unit.
GENERAL DESCRIPTION
The T2 is a self contained unit designed for the
transfer and control of power. It provides an in-
finitely variable speed range between zero and
maximum in both forward and reverse modes
of operation.
This transaxle uses a variable displacement
pump with a maximum displacement of 8cc
per revolution, and motor with a fixed dis-
placement of 10.2cc per revolution. The vari-
able displacement pump features a trunnion
mounted swashplate with a direct-proportional
displacement control. Reversing the direction
of the swashplate reverses the flow of oil from
the pump and thus reverses the direction of the
motor output rotation. The pump and motor are
of the axial piston design and utilize spherical
nosed pistons which are held against a thrust
race by internal compression springs.
DESCRIPTION AND OPERATION

T2™ 3
Figure 1, T2 Hydraulic Schematic
DESCRIPTION AND OPERATION (CONTINUED)
HYDRAULIC SCHEMATIC
Figure 1 is a schematic of the hydraulic oil
circuit. The oil supply for the hydraulic system
of the T2™is also utilized for lubricating the
components of the final drive assembly.
The input shaft and pump cylinder block are
turned in one direction only by the engine/drive
belt/pulley combination. Output of the oil flow is
controlled by the direction and amount that the
variable swashplate is angled. As the pump pis-
tons compress they force the oil to flow through
one of two passageways (forward or reverse) in
the center section to the motor cylinder block
and motor shaft. Since the motor has a fixed
displacement angle it is forced to turn with the
flow of oil. As the angle of the pump swashplate
is increased the amount of oil being pumped will
increase and cause a higher speed output of the
motor. Reversing the angle of the swashplate
will reverse the direction of oil flow.
During the operation of the transaxle, fluid
is “lost” from the hydraulic loop through leak
paths designed into the product for lubrication
purposes (around pistons, under the rotating
cylinder blocks, etc.). This “lost” fluid returns
to the transaxle housing, then is pulled back
into one of the check valves depending upon
the direction of vehicle operation. All of this
oil must pass through an internal filter.
The motor cylinder block mounts onto a splined
motor shaft which drives the gear train.
The bypass feature in the T2 has a mechanical
lever which lifts the motor block off the center
section running surface. This allows oil flow
from the cylinder blocks to be discharged.

4 T2™
EXTERNAL FEATURES T2™
— Top View —
— Inboard View —
Bypass Arm
Oil Fill Plug
Control Arm
Input Shaft
Main HousingSide Housing
RH Axle LH Axle
RH Axle LH Axle
Expansion Tank
Input Shaft
Expansion Tank
Side Housing Main Housing
Control Arm
Brake Arm

T2™ 5
EXTERNAL FEATURES T2™
— Outboard View—Left —
— Outboard View—Right —
Expansion Tank
Bypass Arm
Fan
Pulley
Brake Arm
Brake Rotor
RH Axle
Oil Fill Plug
Expansion Tank
Control Arm
Bypass Arm
LH Axle

6 T2™
Figure 2, Configuration Label
PRODUCT IDENTIFICATION
The model and configuration of the T2 can be determined from the label shown below.
TECHNICAL SPECIFICATIONS
HYDRO-GEAR
T2-AABC-2X1A-1CXX T2-AABC-2X1A-1CXX
6 352 K1 476 Assembled in USA
BOM Model Number
Year Built
Date (Julian- Day of year) Serial Number (unique for that model - for that day)
Type of Product and Build Information
Sales Drawing Number
T2™TECHNICAL SPECIFICATIONS
Overall Transaxle Reduction 20.6 22.7
Input Speeds
Maximum Hi-Idle (No Load)
Minimum
3000 rpm
1800 rpm
Output Torque
Peak
Continuous
395 lb-ft (536 N-m)
105 lb-ft (142 N-m)
425 lb-ft (576 N-m)
115 lb-ft (156 N-m)
Weight on Tires (per unit)
Maximum with 16” tires
Maximum with 18” tires
540 lb (245 kg)
—
—
500 lb (227 kg)
Axle Shaft Diameter .75 in (19.05 mm)
Axle Shaft End Options Keyed or Two Flats
Parking Brake Type Disc
Weight of Unit 28 lb (12.7) kg
Maximum Tire Diameter 16 in (406 mm) 18 in (457 mm)

T2™ 7
This symbol points out important safety
instructions which, if not followed, could en-
danger the personal safety and/or property of
yourself and others. Read and follow all instruc-
tions in this manual before attempting mainte-
nance on your transaxle. When you see this
symbol - HEED ITS WARNING.
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or
maintenance procedures could result in
personal injury, or damage to the equip-
ment. Before servicing or repairing the
T2™transaxle, fully read and understand
the safety precautions described in this
section.
PERSONAL SAFETY
Certain safety precautions must be observed
while servicing or repairing the T2. This section
addresses some of these precautions but must
not be considered an all-inclusive source on
safety information. This section is to be used in
conjunction with all other safety material which
may apply, such as:
1. Other manuals pertaining to this machine,
2. Local and shop safety rules and codes,
3. Governmental safety laws and regula-
tions.
Be sure that you know and understand the
equipment and the hazards associated with it.
Do not place speed above safety.
Notify your supervisor whenever you feel there
is any hazard involving the equipment or the
performance of your job.
Never allow untrained or unauthorized person-
nel to service or repair the equipment.
Wear appropriate clothing. Loose or hanging
clothing or jewelry can be hazardous. Use the
appropriate safety equipment, such as eye
and hearing protection, and safety-toe and
slip-proof shoes.
Never use compressed air to clean debris from
yourself or your clothing.
TOOL SAFETY
Use the proper tools and equipment for the
task.
Inspect each tool before use and replace any
tool that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure
it is well lit, that extra tools are put away, trash
and refuse are in the proper containers, and dirt
or debris have been removed from the working
areas of the machine.
The floor should be clean and dry, and all ex-
tension cords or similar trip hazards should be
removed.
SERVICING SAFETY
Certain procedures may require the vehicle to
be disabled in order to prevent possible injury
to the servicing technician and/or bystanders.
The loss of hydrostatic drive line power may
result in the loss of hydrostatic braking capa-
bility.
Some cleaning solvents are flammable. Use
only approved cleaning materials: Do not use
explosive or flammable liquids to clean the
equipment.
To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition
may be present.
Discard used cleaning material in the appropri-
ate containers.
SAFETY

8 T2™
TROUBLESHOOTING
In many cases, problems with the T2™are
not related to a defective transaxle, but are
caused by slipping drive belts, partially engaged
bypass valves, and loose or damaged control
linkages. Be sure to perform all operational
checks and adjustments outlined in Service and
Maintenance, before assuming the transaxle
is malfunctioning. The table below provides a
troubleshooting checklist to help determine the
cause of operational problems.
WARNING
Do not attempt any servicing or ad-
justments with the engine running.
Use extreme caution while inspecting
the drive belt assembly and all vehicle
linkage!
Follow all safety procedures outlined in
the vehicle owner’s manual.
TROUBLESHOOTING CHECKLIST
Possible Cause Corrective Action
Unit Operates In One Direction Only
Control linkage bent or out of adjustment Repair or replace linkage, Page 9
Drive belt slipping or pulley damaged Repair or replace drive belt or pulley, Page 9
Vehicle Does Not Drive/Track Straight
Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure
Control linkage bent or out of adjustment Repair or replace linkage, Pages 9 and 12
Bypass assembly sticking Repair or replace bypass, Page 28
Brake Partially Engage Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Is Noisy
Oil level low or contaminated oil Fill to proper level or change oil, Page 10
Excessive loading Reduce vehicle loading, Page 9
Loose parts Repair or replace loose parts
Bypass assembly sticking Repair or replace linkage, Page 9
Air trapped in hydraulic system Purge hydraulic system, Page 11
Brake Partially Engage Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Has No/Low Power
Engine speed low Adjust to correct setting
Control linkage bent or out of adjustment Repair or replace linkage, Page 9
Drive belt slipping or pulley damaged Repair or replace drive belt or pulley, Page 9
Oil level low or contaminated oil Fill to proper level or change oil, Page 10
Excessive loading Reduce vehicle loading, Page 9
Bypass assembly sticking Repair or replace linkage, Page 9
Air trapped in hydraulic system Purge hydraulic system, Page 11
Brake Partially Engage Disengage Brake, Replace Broken or Missing Brake Return Spring
Unit Is Operating Hot
Debris buildup around transaxle Clean off debris, Page 9
Cooling fan damaged Repair or replace cooling fan, Pages 17
Oil level low or contaminated oil Fill to proper level or change oil, Page 10
Excessive loading Reduce vehicle loading, Page 9
Air trapped in hydraulic system Purge hydraulic system, Page 11
Brake Partially Engage Disengage Brake, Replace Broken or Missing Brake Return Spring
Transaxle Leaks Oil
Damaged seals, housing, or gaskets Replace damaged components
Air trapped in hydraulic system Purge hydraulic system, Page 11

T2™ 9
SERVICE AND MAINTENANCE
NOTE: Any servicing dealer attempting a
warranty repair must have prior
approval before conducting main-
tenance of a Hydro-Gear®product
unless the servicing dealer is a cur-
rent Authorized Hydro-Gear Service
Center.
EXTERNAL MAINTENANCE
Regular external maintenance of the T2™
should include the following:
1. Check the vehicle operator’s manual for
the recommended load ratings. Insure
the current application does not exceed
load rating.
2. Check oil level in accordance with Figure 3
Page 10.
3. Inspect the vehicle drive belt, idler pulley(s),
and idler spring(s). Insure that no belt
slippage can occur. Slippage can cause low
input speed to the transmission.
4. Inspect the transmission cooling fan for
broken or distorted blades and remove any
obstructions (grass clippings, leaves, dirt,
etc.).
5. Inspect the axle parking brake and vehicle
linkage to insure proper actuation and
adjustment of the parking brake.
6. Inspect the vehicle control linkage to the
directional control arm on transaxle. Also,
insure the control arm is securely fastened
to the trunnion arm of the transaxle.
7. Inspect the bypass mechanism on the
transaxle and vehicle linkage to insure it
actuates and releases fully.
SERVICE AND MAINTENANCE
PROCEDURES
All the service and maintenance procedures
presented on the following pages can be
performed while the T2 is mounted on the
vehicle. Any repair procedures as mentioned
in the repair section of this manual must be
performed after the unit has been removed
from the vehicle.
FLUIDS
The fluids used in Hydro-Gear products have
been carefully selected, and only equivalent, or
better products should be substituted.
Typically, an engine oil with a minimum rating
of 55 SUS at 230°F (110° C) and an API
classification of SL is recommended. A 20W-50
engine oil has been selected for use by the factory
and is recommended for normal operating
temperatures.
FLUID VOLUME AND LEVEL
Fluid volume information is provided in the
Table below.
Certain situations may require additional fluid
to be added or even replaced. Refer to Page
10, Figure 3 and pages 4 and 5 for the proper
fill port location.
Fill the T2 to the bottom of the oil fill port
threads.
Recheck the fluid level once the unit has been
operated for approximately 1 minute.
Purging may be required. Refer to the purging
procedures on page 11.
Fluid Description
20W50 engine oil
Volume – per Transaxle
69.3 fl.oz. (2050 ml) to 65.9 fl.oz. (1950 ml)

10 T2™
This transaxle is factory filled, sealed and does
not require oil maintenance. However, in the
event of oil contamination or degradation, oil
addition or change may alleviate certain per-
formance problems.
1. Remove the transaxle from the vehicle.
2. Clean the expansion tank and oil fill port
areas of any debris.
3. Remove the oil fill port fitting.
4. Position the transaxle so the oil will drain
completely out of the housing.
5. After all the oil is drained from the transaxle,
remove the expansion tank by removing the
self tapping bolt (10-32 x ½) and ratchet
fastner that holds the tank to the housing.
6. Remove the tank and drain the oil from the
tank. DO NOT remove the vent cap from the
tank. DO NOT remove the tank hose or
o-ring unless a replacement is needed.
7. Install the tank by first inserting the hose
into the opening in the expansion tank.
Push the tank opening over the o-ring to
ensure a proper seal.
8. Install the tank and self tapping bolt making
sure not to cross thread the bolt. Torque the
bolt to the lower value of the torque speci-
fication listed in the Table on page 15.
9. Fill the transaxle at the oil fill port according
to Figure 3.
10.Install the oil fill port fitting.
EXPANSION TANK FUNCTION
The expansion tank allows the T2™ to operate
free of air entrainment and provides maximum
lubrication to the mechanical and hydraulic
components in the transaxle.
As the T2 transaxle is operated, oil in the
transaxle housing heats up which causes the
oil to expand. The oil flows through an internal
hose to the bottom of the vented expansion
tank. As the oil cools, the oil in the transaxle
housing contracts, causing the oil level to go
down in the housing. This creates a nega-
tive pressure in the housing causing the oil
to be drawn back into the case. This keeps
the transaxle housing full of oil at specified
operating temperatures.
FLUID CHANGE PROCEDURE
Figure 3, Expansion Tank
Oil Volume
2050 ml (69.3 fl. oz.)
1950 ml (65.9 fl. oz.)
Expansion Tank
1.25
.50 Oil Level
Top of Fill Port

T2™ 11
PURGING PROCEDURES
Due to the effects air has on efficiency in
hydrostatic drive applications, it is critical that
it be purged from the system.
These purge procedures should be imple-
mented any time a hydrostatic system has
been opened to facilitate maintenance or any
additional oil has been added to the system.
Air creates inefficiency because its compres-
sion and expansion rate is higher than that of
the oil approved for use in hydrostatic drive
systems.
The resulting symptoms in hydrostatic systems
may be:
1. Noisy operation.
2. Lack of power or drive after short term
operation.
3. High operation temperature and excessive
expansion of oil.
Before starting, make sure the transaxle/trans-
mission is at the proper oil level. If it is not, fill
to the specifications outlined on page 9.
The following procedures should be performed
with the vehicle drive wheels off the ground,
then repeated under normal operating condi-
tions.
1. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse directions
(5 to 6 times), as air is purged from the unit,
the oil level will drop.
2. With the bypass valve closed and the
engine running, slowly move the directional
control in both forward and reverse
directions (5 to 6 times). Check the oil level,
and add oil as required after stopping
engine.
3. It may be necessary to repeat Steps 1 and 2
until all the air is completely purged from the
system. When the transaxle moves forward
and reverse at normal speed purging is
complete.

12 T2™
WARNING
POTENTIAL FOR SERIOUS INJURY
Certain procedures require the vehicle engine
to be operated and the vehicle to be raised off
the ground. To prevent possible injury to the ser-
vicing technician and/or bystanders, insure the
vehicle is properly secured.
RETURN TO NEUTRAL SETTING
The return to neutral mechanism on the trans-
mission is designed to set the directional con-
trol into a neutral position when the operator
removes their foot from the foot control. Follow
the procedures below to properly adjust the
return to neutral mechanism on the transaxle:
1. Confirm the transaxle is in the operating mode
(bypassdisengaged). Raisethe vehicle’sdrive
tires off the ground to allow free rotation.
NOTE: It may be necessary to remove the
drive tire from the axle hub to access
the linkage control and the transaxle
return arm.
2. Remove the Original Equipment Manufac-
turer’s (OEM’s) control linkage at the control
arm. Refer to Figure 4.
WARNING
Do not attempt any adjustments with the
engine running. Use extreme caution while
inspecting all vehicle linkage!
Follow all safety procedures outlined in the
vehicle owner’s manual.
3. Start the engine and increase the throttle to
full engine speed.
4. Check for axle rotation. If the axles do not
rotate, go to Step 5. If the axles rotate, go
to Step 6.
5. Stop the vehicle’s engine. Reattach and
adjust the OEM linkage according to
the OEM manual. Recheck according to
Step 3 and 4. Stop the vehicle engine.
Refer to Figure 4.
6. Note the axle directional movement. Stop
the vehicle engine. Loosen the lock down
screw (168) until the control arm (160) can
be rotated. Rotate the control arm in the
same direction of the wheel rotation in small
increments. Tighten the lock down screw.
Recheck according to steps 3 and 4. Refer
to Figure 4.
Figure 4, Return to Neutral
Spring (167)
Screw (41)
Scissor Arm (162)
RTN Control Arm (160)
Lock Down Screw (168)
RTN Neutral Arm (161)
Bushing (165)

T2™ 13
Figure 6, Friction Pack Adjustment
BRAKE SETTING
1. Remove the brake arm bias spring(134),
and then the cotter pin (133) securing the
brake castle nut (132).
2. Insert a 0.020” feeler gage between the
brake rotor (121) and top brake puck, and
then set the brake by finger tightening or
loosening the castle nut.
3. Install a new cotter pin to secure the castle
nut, and then install the brake arm bias
spring.
FRICTION PACK ADJUSTMENT
The friction pack dampens or holds the operator
control lever in its desired position.
Adjustment for the amount of drag or holding
force can be made by turning the friction pack
nut in or out.
Adjustments should be made in no more than
1/4 turn increments.
Over-tightening will result in difficulty or inability
of the operator to move the control lever.
NOTE: The factory setting for the friction
pack is tightening of the friction pack
nut to 100 in-lbs (11 Nm) torque. The
friction pack nut is then backed off
per the vehicle manufacturer’s
specifications.
BRAKE MAINTENANCE
Figure 5, Brake Setting
(121) (124)
(130)
(134)
(133)
(132)
Friction Pack Nut

14 T2™
TEAR DOWN AND REASSEMBLY
HOW TO USE THIS MANUAL
Each subassembly illustrated in this section
is illustrated by an exploded view showing
the parts involved. The item reference num-
bers in each illustration are for assembly
instructions only. See page 36 for part names
and descriptions. A complete exploded view
and item list of the transaxle is provided on
pages 35 and 36.
Many of the parts and subassemblies of this
transaxle can be removed and serviced inde-
pendently of other components. Where some
components and assemblies must be removed
before a given assembly can be serviced, that
information is given at the beginning of the
disassembly instructions.
GENERAL INSTRUCTIONS
Cleanliness is a primary means of assuring
satisfactory life on repaired units. Thoroughly
clean all exposed surfaces prior to any type
of maintenance. Cleaning of all parts by us-
ing a solvent wash and air drying is usually
adequate. As with any precision equipment, all
parts must be kept free of foreign material and
chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
Upon removal, it is recommended that all seals,
O-rings, and gaskets be replaced. During
installation lightly lubricate all seals, O-rings,
gaskets with a clean petroleum jelly prior to
assembly. Also protect the inner diameter of
seals by covering the shaft with a cellophane
(plastic wrap, etc.) material. Be sure all rem-
nants of this covering are removed after ser-
vicing.
Parts requiring replacement must be replaced
from the appropriate kits identified in the Items
Listing, found on page 36. Use only original
Hydro-Gear®replacement parts found listed
in BLN-51427 (CD).
IMPORTANT: When internal repair is performed
on the T2™, the filter assembly must be re-
placed.
TRANSAXLE REMOVAL
It is necessary to remove the T2 from
the vehicle before performing the repair
procedures presented in this section.
LIMITED DISASSEMBLY
The following procedures are presented in
the order in which they must be performed to
completely disassemble the unit. Do not
disassemble the unit any farther than is
necessary to accomplish the required repairs.
Each disassembly procedure is followed by a
corresponding assembly procedure.
Reassembly is accomplished by performing
the “Assembly” portions of the procedures. If
the unit has been completely disassembled, a
summary of the assembly procedures, in the
order in which they should occur, is given on
page 33.

T2™ 15
TOOLS
As a general rule, use the low end of the torque spec on fasteners when
reassembling the unit.
TORQUES
REQUIRED TOOLS
Miscellaneous Sockets
Flat Blade Screw Driver (2) 1/2”-3/8” Adapter
Torque Wrench 1/2” Deep
Air Impact Wrench 7/16” Deep
Rubber or Neoprene Mallet 3/4” Deep
Breaker Bar 7/8” Deep
Side Cutters/Snips 9/16” Deep
Needle Nose Pliers T-40 Torx Head
Large External Snap Ring Pliers 10 mm
Small Internal Snap Ring Pliers
REQUIRED TORQUE VALUES
Item Description Torque Operation
8 HFHCS 1/4-20 x 1.25 105-155 in-lbs [11.8-17.5 Nm] Housing screw
13 Plug 9/16-18 (Metal) 180-240 in-lbs [20.3-27.1 Nm] Fill plug
22 Bolt, Hex Flange, 3/8-16, CS 525-700 in-lbs [59.3-79.1 Nm] Center section bolt
24 Check plug 280-400 in-lbs [31.6-45.2 Nm] Check plugs
25 Check plug 280-400 in-lbs [31.6-45.2 Nm] Check plugs
41 TWHCS 5/16-18 x 1 230-310 in-lbs [25.9-35.0 Nm] Trunnion arm screw
43 Screw, set 5/16-24 x 2.50 135-155 in-lbs [15.2-17.5 Nm] Control arm stud
49 Nut, hex 5/16-24 nylon insert 85-120 in-lbs [9.6-13.5 Nm] Friction Pack Nut
127 HFHCS 1/4-20 x 2.0 w/ patch 80-120 in-lbs [9.0-13.5 Nm] Brake yoke screw
128 HHCS 1/4-20 x 1 (patch) 80-120 in-lbs [9.0-13.5 Nm] Brake yoke screw
140 5/16 SAE, 5/32 tube 96-120 in-lbs [10.8-13.5 Nm] Expansion tank fitting
144 Bolt, self-tapping 10-32 x 0.5 25-50 in-lbs [2.8-5.6 Nm] Expansion tank screw
152 Nut, Hex Lock 1/2-20 360-520 in-lbs [40.7-58.8 Nm] Fan Nut
153 HFHCS 1/4-20 x 0.75 50-80 in-lbs [5.7-9.0 Nm] Fan Screws
168 Lock Down Screw 135-155 in-lbs[15.3-17.5 Nm] RTN Arm

16 T2™
NOTE: It is necessary to remove the T2™from
the vehicle before performing the repair
procedures presented in this section.
Before starting any disassembly, make
certain that your work area is neat and
clean. Clean the external parts of the
transaxle.
The following procedures are pre-
sented in the order recommended for a
complete tear down of the transaxle.
Figure 7, T2 Transaxle
TRANSAXLE REMOVAL
Do not disassemble the unit any far-
ther than necessary to accomplish the
required repairs.
Reassembly is accomplished by per-
forming the “Assembly” portions of the
procedures. If the unit has been com-
pletely disassembled, a summary of
the assembly procedures, in the order
in which they should occur, is given on
page 33.

T2™ 17
Refer to Figure 8
PULLEY AND FAN CONFIGURATION
1. Remove the locknut (152), and detach the
fan and pulley assembly from the input
shaft.
2. Separate the assembly by removing the
screws (153), fan (150) and the pulley
(151).
Inspection
1. Check all components for wear or damage.
Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order
of disassembly.
2. When tightening the fasteners, refer to the
table on page 15 for the required torque
values.
NOTE: As a general rule, use the low end of
the torque specification on fasteners
when reassembling the unit.
Refer to Figure 9
FAN AND PULLEY CONFIGURATION
1. Remove the locknut (152) and washer
(153).
2. Remove the fan (150) and the pulley
(151).
Inspection
1. Check all components for wear or damage.
Replace if necessary.
Assembly
1. Reassemble all parts in the reverse order
of disassembly.
2. When tightening the fasteners, refer to the
table on page 15 for the required torque
values.
Figure 8, Fan on bottom configuration Figure 9, Fan on top configuration
FAN AND PULLEY
152
153
150
151
152
151
150
153

18 T2™
Fig. 10 Expansion Tank
EXPANSION TANK
145
147
144
143
141
146
Refer to Figure 10
Disassembly
1. Remove all items previously discussed in
their recommended order.
2. Remove the ratchet fastener (147) and
discard.
3. Detach the tube (145) from the tank fitting
(146). The fitting (146) does not need to be
removed – unless, replacing.
4. Remove the screw (144) from the expansion
tank.
5. Remove the tank (143). Do not remove the
hose (141) at this time.
Inspection
1. Inspect all parts for wear or damage. Re-
place if necessary.
Assembly
1. Reassemble all parts in the reverse order
of disassembly.
2. When tightening the fasteners, refer to the
table on page 15 for the required torque
values.
NOTE: As a general rule, use the low end of
the torque specification on fasteners
when reassembling the unit.