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Troy-Bilt Horse Tiller Clutch Roller Assembly Upgrade & Rebuild

Upgrading for a permanent fix for an obsolete part.
troy-bilt horse tiller clutch roller assembly
Roller Assembly

Worn out clutch roller assembly. Note the flat side on the solid steel roller, & extreme wear on the mechanical linkage parts.

troy-bilt horse clutch roller block
Roller Block

Excessive wear on roller surface.

troy-bilt horse tiller clutch roller block
Roller Block

Extreme wear (grooved) on bottom of roller block where the bearing rest while tilling.

Removing Rivets From Roller Assembly Linkage

Carefully grind heads of rivets & tap them out with a hammer & drift.
grinding rivets troy-bilt horse clutch linkage
grinding rivets troy-bilt horse tiller clutch linkage
tapping out rivets troy-bilt horse tiller clutch linkage
all rivets removed troy-bilt horse tiller clutch linkage

Soak Parts in Chem-Dip

Optional, but highly recommended. Clean them up somehow.
chem dip
tiller clutch linkage parts in chem dip basket
submersing tiller clutch linkage parts in chem dip for a soak

Drill out bearing axle holes in linkage to 10mm

New ball bearing has a 10mm inside diameter for axle bolt which is significantly larger than the original solid steel wheel axle. The linkage must be drilled out to 10mm for the new upgraded ball bearing.
drilling oversized 10mm bearing axle holes in linkage
Bolt the two linkage parts together & drill them at once to ensure proper alignment.
cleaning oversized axle holes with a countersink
Use a countersink to clean up the newly drilled holes.
cleaning linkage parts with wire wheel
Use a grinder & wire wheel to clean up linkage parts.
wire wheel cleaning linkage parts
Clean to bare metal for painting.

Filling worn roller block grooves with weld.

This procedure may or may not be necessary. It all depends on how much wear the block has been subjected to. Mild wear can be cleaned up without filling with material. A sanding wheel on an angle grinder works well. A belt or disc sander can be used as well.
roller block in vise
Worn roller block.
heating roller block with torch
Heat cast roller block before welding.
building weld on worn roller block
Fill worn area with welding rod.
grinding weld flush on roller block
Grind & file new clean surface on roller block.
new cleanly machined surface on roller block
Clean, flatten, & polish roller block.

Painting & assembling the newly upgraded roller assembly.

painted linkage parts
Paint linkage parts & roller block.
painted linkage parts
Prepare parts for assembly. Apply a light coat of vaseline (recommended) or grease on flat washers & machine washers.
assembled roller assembly with new ball bearing
Use 4 washers on each bolt (washers are used as spacers between linkage, as well as on bolt heads & nuts). Machine washers are for the bearing, & flat washers are for the linkage bolts.
assembled roller assembly
Assembled roller assembly.

Days until spring (Vernal Equinox)

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