KAMA 554 Front Drive Repair

3RRL · Jan 13, 2008

Some of you know how I have used my Kama 554 in land preparation for my new log home, garage and barn. I have just over 420 hours on the meter, but more actual hours than that since the meter was not working for a couple months when I first got it. From estimates I got for all the dirt work, the Kama 554 has paid for itself already more than double (conservatively even more than that?). That is not to count the many hours I have maintaining my 1/2 mile long dirt road and all the other projects over the last 3 years.

In the thread
Three Rivers Home and Barn Project
I mentioned breaking the front drive while working in the mud in 4 wheel drive. I was shifting vigorously from forward to reverse to get the mud moved off my road, trying to get out of the heavy rain storm. In addition, I had a loader full of mud for added traction (about 2500 lbs at least) which is a definite NO-NO for 4wd systems. I had been warned several times that damage might occur to the front drive but I ignored the warnings ... and that's exactly what happened.

Anyway, here is the start of the thread for the repairs.

3RRL · Jan 13, 2008

I will include many photos since this project is quite involved. However not so bad that one should steer away from it. It is very doable, even for an old hack like myself at my rural campsite.

Upon dis-assembly, I saw that the tie rod ends, the swivel ball shaft was worn too. Probably due tot he same reason ... exposure to heavy loads in the front end loader bucket and also to climbing over rocks and obstacles. That places a great amount of stress on the steering linkage. After jacking up the front up with the bucket and securely blocking it with big wood, I proceeded to drain and split the front wheel drive assemblies. There are drains in each front wheel drive and also on under the differential . I also had to drain the entire front differential casing to get rid of the steel chips in there. I still have to wash it all out with Kerosene before re-assembling.

3RRL · Jan 13, 2008

Since I actually did the dis-assembly back in December, I might accidentally skip a step or two, so if you have questions, please ask.
I also wanted to add that I did have the Kama operation and parts manual to work with, but there were no instruction on how to do this exactly. So I had to "feel" my way through the dis-assembly as I went along and using only those tools I had at my rural camp.

The other thing I did was order all the parts before I even started the dis-assembly by looking at the parts manual. I ordered every component for both sides, gears, shafts, bearings , spacers, seals, "o" rings etc. everything I thought was associated with the front drive even the front differential drives and shafts which you'll see in these photos. I ordered them through my good friend Scott (flyhiflylo) and he added them to the existing order for Loretta's tractor (284 Jinma). He quoted me an outstanding price for all the components and on top of that, told me it would be NO CHARGE from his Kama representative. How's THAT for a good service deal?
Thanks Scott!!!

3RRL · Jan 13, 2008

I could feel when I did the damage. The tractor lurched and missed a beat as the front drive felt like it had busted a tooth while operating. Of course I was a half mile from camp and in the rain and not quite done with my chores. I decided (against better judgment of course) to continue working the road so my contractors could get up it the next day.

Well I kept grinding those gears in the front end to shmush even more. It did no good to take it out of 4 wheel drive after it broke, because then the front wheels locked up. So I put it back in 4 wheel drive, finished the road work and drove it back to camp. Brutal!!
Every once in a while the right front wheel would stop turning but the tractor just pushed it as it skidded forward. Then I'd stop and back up to loosen the jam and go forward again. I had to do this several time before I got back to camp. All this time KNWOWING my front drive would be toast. That is why I say I tortured the tractor beyond all reasonable doubt. I butchered it.

Now, here are some pictures showing some of the wear and breaks.

I kept working my way back but so far the large ring gear and miter gear seemed OK. They are hardened. Finally, the vertical shaft which transmits power from the front drive shaft to the large ring gear was galled.

Flyhiflylo · Jan 13, 2008

Yeah! free is good!

3RRL · Jan 13, 2008

Yeah, for sure Scott!

It's the miter gears that are shot. I'm sure the broken teeth started rubbing around the shaft and started galling it. The large ring gear and it's mating miter gear were OK, but when I pulled off the top of the wheel drive, this is what I saw.

Those are the right side where the wheel locked up. Those gear teeth are completely ground off. However, when I pooped off the left side, evidence of the same thing happening, except the teeth were not completely gone yet. Looks like they (the Chinese) might have made these "soft" on purpose to minimize damage in the drive train in the front? They are the smallest and least expensive to replace.
This is the left front drive.

bluechip · Jan 13, 2008

Rob, I cant compete with Scotts pricing, but if there is anything you find anything you missed, there is a good chance we have it in stock. Following the picutres so far, I'm not seeing what part broke. The front end on the KAMAs have been very tough. We have seen a couple T joint housings break and the tie rod ends seem to be the weak link in the steering.

Looks like if I make the Tulare show, I'll be in Fresno, cant get a room closer.

bluechip · Jan 13, 2008

OK, while I was typing, you were adding more pictures.... even my middle aged eyes can see the damage now!

3RRL · Jan 13, 2008

I went a little further with the dis-assembly taking off the gear from the front drive shaft and then removing the drive shaft from the front differential. Here's a shot of all the gears from just one side front drive unit.

That's about as far as I got before taking a break later that night. I will have to inspect the front differential gears too, but I'm pretty sure they are OK. In rotating the shafts, it felt pretty smooth. If they are OK, I will leave them, but in any case, I will flush out the drive shaft housing.

In a couple weeks the new parts will arrive and my good fried Larry (gugliols) is coming out for a visit. He will help me put this thing back together. We will also be working on the new (Loretta's) tractor and implements.

Mike058 · Jan 13, 2008

This is pretty fascinating stuff. I notice snap rings are used to hold the one gear on. Any other fasteners besides nuts and bolts holding things together? The other thing I'm wondering about is if you're going to use the front wheel drive for loader work now? I mean, after seeing what's involved to repair it, do you think it's worth it?