Cush Drive Rebuild

• Drill Press
• Safety Glasses
• Ball Peen Hammer
• Rubber Hammer
• Flat Head Screwdriver
• Pick tool
• Small Punch
• Center Punch
• Pliers
• Circlip Pliers
• Channel Locks
• Vice

• To test the Cush Drive shake it
• If it makes noise the Springs inside are broken

• This step will happen when you take the Cush Drive out of the motor, this is for demonstration purposes only
• Push the threaded side of the Cush Drive Spindle

• With you other hand catch the Roller Bearings
• Inspect the roller bearings. There should be 21 to 24 depending on your model.

SET the Cush on the vice DO NOT tighten it

Pull the Circlip that retains the bearing

Flip it over

• With a Rubber Hammer gently tap the Cush Drive Spindle
• Make sure the vice is open larger than the bearing on the other side
• This will push the bearing out

The Bearing and Cush Drive Spindle will be stuck together you will need to separate them

• SET the Bearing and Spindle on the vice
• DON'T TIGHTEN

Tap the Spindle and it will come free from the Bearing

Inspect the Threads on the Cush Drive Spindle REPLACE if they are damaged

Now you are going to drill out the Rivets

With a Center Punch tap each rivet

You are making a guide for the drill bit to go directly into the center of the rivet

To start drill off the heads of the (6) rivets (7/32 drill bit)

Lift off the metal plate

Now you can see the springs

• Pull them out with your small screwdriver
• If they are broken they should just fall out

• Spin the Outer Gear
• Pull up on the Inner Gears

Drill out the center of the rivets (5/32 drill bit)

• Be Careful it is very easy to break the bit
• Drill slowly
• The rivet is softer than the gear you will be able to hear when you are drilling into the gears if this happens stop and reposition it

Pull the back plate off

• Clean EVERYHING
• BLOW off all the metal shavings

• Put the 2 gears back together
• BE CAREFUL you can put it together upside down

THIS IS INCORRECT

This is what it should look like (no lip)

Install the NEW Springs out of your Rebuild Kit

To install the NEW Springs compress them with the Cahnnel Locks and tap them with your hammer

This is what it should look like when you are done

Install the NEW Back Plate

Install the NEW Rivets

Install the NEW Top Plate

To lock them in I like to use a vice to get them started

Set the back part of the Rivet against the vice and peen the rivets with you ball peen hammer.

It should look like this

Install the Cush Drive Spindle with this side down (so the threads are sticking up)

A little bit of Grease will help the bearing go in

Use a Large socket to tap it in

Install the Circlip

• Note: This step will actually happen when you install the drive into the motor but Ill show you now for demonstration purposes.
• Grease the bearing race

Grease your finger

Now the bearings will stick to your finger

Place them into the race

Tap the Cush Drive Spindle into the