3011 transmission surgery

Renze · Oct 27, 2007

I bought a 3011 last week, the engine runs superb, it shifts smooth, only the rear mudguards were partially rotten, and the guy who tried to fix that up did a dreadful job...

when i got it home i took it for a drive, and found that the 4th gear was ticking.... closer inspection learned that a teeth of the 4th gear went missing....

Today i took it in half and rolled away the engine.
coming week i need to split the rear axle from the tranny, to pull out the layshaft from behind.

I have never been this deep into a gearbox before, so maybe one of you guys may know:

Can i take off the rear axle by loosening the bolts and taking off the PTO/oil pump shift lever, or do i have to remove parts from the pinion shaft as well ???

And do i really need the special puller, to pull out the reduction gear layshaft, or is there a standard tool that will substitute ?
It seems that this special tool is hard to get.

zetor3545 · Oct 28, 2007

hi renze
when you split the backend from the tranny the pto gear will fall off into the bottom of the box. easy access to is to remove the tin plate underneath . when you pull the backend from the tranny it will just fall. to put it back toghether you need 2 people one to hold the backend and the other underneath holding the gearin the correct place and all should be ok.

we found on my 3545 when i bought her her pto did not work this was why backend was split and the gear fell off noone realised just put it back toghether now she works a treat.

matt

Renze · Oct 28, 2007

If you mean the sleeve shaft, you dont have to split the tractor to install that... taking the 3pt hitch cover is enough to stick the main PTO shaft into the sleeve shaft from behind...

anyways, so if i split it, i can loosen the bolts and take it apart, the pinion shaft with the inner bearing race will stay in the main transmission, and the outer race will stay in the rear axle ?

I dont know many people who opened up a tranny this far, A. because most people are afraid to do it, and B. because a broken gear normally is impossible. I think i had this chance of 1 in 10.000 material failure.

dave_peters · Oct 29, 2007

Renze, It may be an idea to find out why the tooth broke off the gear. When we had a 5545 it was because the bolt holding the gear selector to the rails dropped out and got between the teeth.
Dave

Renze · Oct 30, 2007

Dave, how did you get the reduction gear layshaft out ?
Did you use the original Zetor puller tool, or a common substitute, or did you make it yourself ?

dave_peters · Oct 31, 2007

It was a long time ago now, 20+ yrs, but I think the shaft was threaded up the end and we made a crude slide hammer and pulled it out that way.
sorry I can't be more helpful
Dave

Renze · Oct 31, 2007

Dave, I only have the workshop manual for the 5245, so on the older models the construction might have been a bit different...

I was just checking the forum to read your reply, before i was going into the shop to bolt the tranny loose from the rear end.
I will see, and maybe take some pics for anyone (forum users) who might need to do this operation also.

.... I think its a good idea to take pictures of all the major repairs i'll do this winter, for all the rest of the folks. The 5245 needs a brake overhaul since last year but i didnt have time nor tools yet..
Last week i bought a 2 ton shop crane on casters, which is definately needed to lift the heavy portals away from underneath the mudguards, as my electric hoist, hanging from a roof I-beam, cant reach there..

I used to be tight on money for tools, but since about a year, i just changed my mind, because without the proper tools, any job is a pain...

Renze · Oct 31, 2007

Matthew, it seems that you're the one that has the freshest memory of how to do this:

I removed all bolts and it wont come off: Do i have to remove the castle nut that holds the pinion ?

I can buy a wrecker with seized engine, for 400 euro... but then i still cant test the transmission untill i hook it up to my own engine...

zetor3545 · Oct 31, 2007

renze let me get this right you have removed the bolts which holds the tranny to the backend??? its a year since i done this but i remember having to remove the hydraulic lift cover because something was not playing ball!!!! i think i had to remove something in order to get tranny to split away! once this hick up was lept over the backend splitted away the pinionn all stayed in complete you had to pull the transmission away about 2 ft because the pto was still coming out of the gearbox. this is when that gear i was on about drops down.

all the best matthew

Renze · Nov 1, 2007

Matthew, this evening i was tired so i was watching the A-team, and Law&Order. Tomorrow i will work on the tractor again and try it:

Do you mean the ring around the pinion bearing, held in place by 3 M8 bolts ?
I also took loose the selector shaft of the PTO sleeved shaft.

What was that held the tractor together after removing the bolts, did it keep the gearbox stuck to the rear end, or did it allow it to move an inch or so and then hang ?

zetor3545 · Nov 1, 2007

i dont remember removing the 3 m8 bolts. you must remove the hydraulic lift cover and i remember having to remove something to allow the tranny to split away completely.

yes the backend will seperate about an 1" and then no more this is why the lift must be removed.

matthew

Renze · Nov 2, 2007

Did it come of easy, or did you have to jerk it out of a press fitting ? I slung the whole tractor but the tranny didnt come off... Maybe i need to pound a screwdriver between both cases.

zetor3545 · Nov 2, 2007

did i have to pound what??

Renze · Nov 2, 2007

I mean, maybe i have to pound a screwdriver between the transmission case and rear axle case, to wedge it off... mine just wont come off...

markku · Nov 3, 2007

Renze,

If the pinion shaft is no needed to remove, as boys says, then there should not be anything else, than pto lever and fork that you have allready removed. It is for sure that you need 2 srew drivers and 2kg hammer It is easier to split tractor from clutch housing, because you can "bend" the joint to loose it with jack (lifting and dropping few times 1mm to each direction).

There is least 2 centering pins, and those have tight fitting.

Renze · Nov 3, 2007

O.k. i have a confession to make:

I broke a screw driver trying to split the rear axle from the gearbox... used the 2kg hammer and nothing happened..

UNTIL i found that i forgot to loosen 1 bolt...

I have taken it out, and took pictures so the next person who needs to split it, know how its done.

zetor3545 · Nov 3, 2007

haha renze well we all make some cockups!! so ahve you actually removed the tranny yet???

matt

Renze · Nov 3, 2007

Yes its in half by now. i put it on some axle stands with a piece of wood to give it some stable ness when i work on it.

Now i need to make myself a gear puller of some pipe, a ring and M16 threaded rod, to pull that reduction gear layshaft out of the gearbox, before i can strip some gears off the main layshaft to get access to that gear.

Markku: i had a quicker method to split it: i pressed the clutch pedal with my foot, so the pressure bearing pressed the clutch and engine right out !!

markku · Nov 8, 2007

Hmm.. that works really fine with old models without hydraulically controlled clutch. Actually, it can work with newer models too, if there is enough movement. Offcourse you can be pumping several times with clutch pedal

Renze · Nov 9, 2007

I dont have time in the evenings right now.
But i still have my extra hours from work, i did take only 2 weeks of summer holiday instead of 3, so i have 9 days to take off before the end of the year.

3011 transmission surgery

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