Great Kohler Engineering

[GTSRider]

Special magnet with 4.45 lb pull arrived in mail today...no luck...
I think shaft is wedged in crank shaft ...
will do a crankcase split now.... yuck...dreading that job ....
but it must be done... all this for a $3 seal ! ! !
Crazy engineering !
All Kohler had to do is drill shaft , and put pin internally so shaft would
not drop into crankcase all on it's own.
Oh well ...keep ya posted on the next phase of the job.

 

[SandburRanch]

I have no idea what the circumstances are you are dealing with but my old wondering mind is wondering if a shop vac could be rigged to a 1/4 OD hose/tubing or similar and suck it out.

Ok, ideas were ask for and that's my best shot.

 

[GTSRider]

Believe it or not.... I thought of a similar idea with a vacuum pump...
but new bad news.... I special ordered a 1/4 " x 3 inch magnet ,with a
4.45 lb pull.... and shaft won't budge !
It must have lodged between crank and crank case when it dropped.
Was looking at Kohler Service manual the other day... and it shows how to remove shat seal WHILE engine is totally dis assembled !
I can only assume.... that this seal was meant to last life of engine...
and being I am not original owner.... this engine got cooked bad at some
point , and destroyed every seal in it.
I replaced both front and rear crank seals.... and then this governor shaft seal blew immediately on start up, and oil gushed out.
But as I said before... I am VERY disappointed in Kohler engineers,
that they designed shaft to free fall into crankcase when retainer spring is removed...thereby... NOT allowing the changing of of a $3 seal that is VERY
accessible, with out splitting crank case !
Unbelievable poor engineering !

 

[Gator6x4]

Removing the front of the engine isn't that much of a job. On some models you can remove the front without loosening the engine cradle bolts on others you have to loosen or remove the four engine cradle bolts. The exhaust, heat shields and PTO have to be removed. Be careful when seperating the surfaces are machine fit and sealed with RTV. The governor will also fall off/out unless you are very careful. Seperate the front from the case, pull back about 1-1/2 -2 inches and look inside on top left you should see the governor meshed with the camshaft gear. Insure the governor comes out with the front of the engine. You may have to rotate the crankshaft to get the governor gear to un-mesh with the camshaft gear. When installing the front, push it in gently until the governor gear contacts the camshaft gear. Then rotate the engine crankshaft slowly while keeping pressure on the front cover to gently ease the governor into mesh with the camshaft gear. Don't over use RTV and be careful with the new crankshaft seal.

 

[GTSRider]

Thanks ...appreciate your tips....
I don't think I will need to remove governor shaft...only free it..
and lift back up to top.... through the new seal, and I will immediately
install washer and retainer spring at proper clearance....then I don't have to worry about the little bastard falling into never never land again.
If Kohler engineers were not asleep...they would have put a one one cent pin
in the shaft to keep it from free falling.
I see that cover is sitting right up against tractor frame.... but
I am hoping I do not have to loosen engine mount bolts.... because on this tractor...they are a ***** to get to....so will try to slide cover out.... but may have to lift engine slightly to get to the 2 lower bolts of case cover.
Have you done this in a Cub 3000 series ?
Pete

 

[Gator6x4]

The governor shaft, or the part that dropped down into the engine is basically a one quarter inch round rod with a ninety degree turn on the bottom end that has been flatten. The governor rod and governor are seperate and different. When you get the front off and the governor rod re-installed you will be able to see the role and function of each. The governor gear is constructed out of plastic and has steel counter weighst that spin out and regulate/maintain engine speed. The governor being constructed out of plastic and subjected to internal engine heat will break easily. The governor is geared and interfaces with the cam gear. I caution you again don't use excessive force when re-installing the front of the engine. Rotate the engine slowly while pressing inward on the front plate. You will feel the governer mesh with the cam gear and the front will slide up snuggly.

 

[GTSRider]

Got front cover loose after removing 10 bolts...... feel I got a lucky break when
I did not have to loosen 4 engine mount bolts.... a ***** on this tractor.
I can not remove cover till I remove PTO tension er assembly...which is tomorrows project. Was only able to move front cover about 2.5 inches,
but saw governor shaft jammed in against weight from crank.
With some hand movement of crank...and some friendly persuasion to the shaft... I got it free, and unharmed.
Can't stop saying , what a poor design it is to have the shaft un- attached to
in cover and free to fall into crankcase as soon as retainer spring is removed
from the top. So I hope to pick up new seal tomorrow, and a tube of RTV....
clean all and re- assemble.
Will also clean crank case breather... as I am suspecting it is clogged and created high crankcase pressures.... enough to blow all engine seals.
Pete

 

[GTSRider]

Ok...latest update.... front crankcase cover is back on, and crank case was amazingly clean....there is no gasket, so I am praying the RTV I used
will seal it. My concern is the bottom ..... because getting cover on is a
tricky balance act of aligning gears, and tapping cover at same time.
because I did not totally remove cover.... there may have been a few drops of oil coming out of oil pump, and if that oil dripped down over bottom edge...
I may have a slow leak at that point.... but we shall see.
Removed crank case breather cover today...only to find breather element...
had literally turned to dust.... this could not be good for anything.
Has anyone ever seen this ? What could cause this ?
And what kind of potential damage could a disintegrated breather
element do ?
More parts to order.... new breather.... and gasket.... also...non-related to
engine.... found front PTO idler bearing was very rough to turn, so ordered a new one.
Man ...after all this... I hope this engine runs ok......
the test will come soon.

 

[GTSRider]

Just came in from fiddling with the never ending project....
got it all back together , and turned the key , and it fired right up...
no visible oil leaks so far....
but here's the bad news..... I must have throttle springs wrong or one missing...
because throttle won't return to idle screw... and engine really races...
so I can't let it run for more than a second.
Anyone have any ideas ?
Thanks..
Pete

 

[GTSRider]

Just looked at Kohler online manual.... maybe I have Governor not adjusted
properly....manual says to push governor lever as far towards carb as it can go, and at same time rotate shaft counterclockwise which I did do....
but don't think I pushed lever towards carb...anyone share some tips ?