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My TB Bronco is 6 months old and it chewed up the upper drive belt. Purchased correct replacement. Have the new belt installed and working. Having problems getting Deck reinstalled. The belt guide on the idler pulley is preventing the right side hanger from moving into place. Also having great difficulty getting the PTO cable connected. Cable seems to be too short to get the spring back into the deck connection. Very frustrated as I'm 67 and don't have the flexibility and hand strength I once had. Any secrets you can share? I've watched several videos on youtube by eReplacementParts.com. My Pony shure doesn't come apart and go back together as easy as theirs does...
Thanks for any help.

Chuck

I took a break and when I came back, the PTO cable and spring magically went into place. Got the left side deck lift connected, but the right side won't go. The belt guide on the idler pulley is interfering with the lift rod. I don't want to take the idler off again because it was such a bi**h to get on with the new belt. Looks like the belt guide is part of the mount for the idler and not adjustable anyway. But why won't it fit?

Chuck

Well I am just as confused as you are from what you have written.
You don't remove anything from the deck apart from the PTO cable to remove it and the owners manual has reasonably easy to follow instructions.
If you have lost yours it can be downloaded for free from Troy Bilt.
The lift arm really can not be fouling on the deck if everything is back in its right position.
So we need to know exactly what you did, step by step so we can try to visualise what may have been put back wrong.
Slip 2 lengths of 2 x 4 under the deck, lower the deck lift till there is no tension on the lift arms and disconnect them then raise the deck height to get them out of the way .
Remove the front drawbar and belt from the engine pulley.
slide the deck on the 2 x 4 part way out to allow easy access to the PTO cable and remove the PTO cable the slide the deck out completely.
Take a couple of photos and post them.
The link below shows the parts breakdown so check you have reinstalled the idler , guide and spacers in the correct order.
http://www.jackssmallengines.com/jacks-parts-lookup/manufacturer/troy-bilt/13-lawn-tractors/2015-models/13wm77ks011-pony-2015/mower-deck-42-inch
IF you left click on the diagram it will come up all by itself and can be printed out to take with you to the shed.

I'm sorry Bert, if I was not clear. I have the manual. In fact, the manual I have does not show the top drive belt that is on my machine, so I downloaded another from the Troy Bilt Website. I also downloaded their parts manual.
I have managed to re-connect the cable and spring, and one side of the deck lifting mechanism. The right side is giving me problems. I did not totally remove the idler pulley, just enough to get the drive belt on. The rod that lifts the right side of the deck is interfering with the belt guide on the idler pulley. What do you not understand? Tomorrow I will try to take pictures of the problem...

Chuck

Didn't take pictures until today, just didn't feel like messing with it yesterday. I'm still very frustrated with this problem. I have attached 2 pictures of the problem, interference area circled in red. The pictures are large, so if you open them in Paint you can zoom in to see the problem.





The lift rod for the right side of the deck is interfering with the belt guard on the small idler pulley. I cannot get the lift rod into position to connect to the deck lifting point. I cannot see a way of adjusting it. Can anyone help? I have loosened the idler pulley bolt as can be seen in the picture. Need to remember to tighten that back down before running the machine.
Meanwhile, my lawn is getting hip deep to a tall man and my $1700.00 mower is useless... I wish I had the funds and means to take it to a pro. I'll never buy MTD anything again.

Chuck

bertsmobile1 said:

The lift arm really can not be fouling on the deck if everything is back in its right position.I agree, but what is out of place? I downloaded the latest manual and followed it step by step.
So we need to know exactly what you did, step by step so we can try to visualise what may have been put back wrong.See Above
IF you left click on the diagram it will come up all by itself and can be printed out to take with you to the shed.

Click to expand...

I did print it and took it to the machine.

I'll be the first to admit I'm not the sharpest tack in the box, but this is so frustrating. My 12 year old hard used Murray was easier to work on than this, and cost a lot less even with the bagger. I have now removed the front Deck lift rod in an attempt to maneuver the deck into position easier. Short of some kind of lifting devise, I can't see how to make working on it easier.
I did go to my local Harbor Freight and get their assortment of hitch pins to replace the hard to remove ones that came on the machine. I've lost enough skin and gotten enough bruises trying to remove the originals. My arms look like I was worked over by a thug with a rubber hose.
I apologize if I sound bitter, but I am!. This is the second Troy Bilt/MTD machine I have had lots of problems with. TB's tech support couldn't fix the last one. I am sooo tired of the continued downward spiral of quality and support for the tools marketed in this country under what used to be quality brand names.

Chuck

Now it is a lot more clearer.
Did you remove the spring that tensions the offending pulley ?
I ask this because that spring looks way too loose and there are a myriad of potential anchour points under the frame as it is used for a dozen or more different models.
Use a strong light and magnifier if need be to find the chaffing where the spring was originally positioned

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http://www.mymowerparts.com/pdf/Troy-Bilt-Troy-Built-Service-Repair-Manuals/

your Bronco repair manual is 10 down

very important to replace both belts if manual so states, if other belt is in good shape keep it for an emergency, what does your owner/operators manual say about belt adjustment?

mechanic mark said:

http://www.mymowerparts.com/pdf/Troy-Bilt-Troy-Built-Service-Repair-Manuals/

your Bronco repair manual is 10 down

Click to expand...

Thanks for the link Mark. today I'm taking the deck back off and going to find a way to lift the front end to get a better view of the layout.

Chuck

I have downloaded the repair manual that Mike linked to. I printed pages 57-59 pertaining to changing the drive belts. I actually have 2 new belts ($60!) as I read the owners manual that I downloaded, and it said to change both drive belts at the same time. The original order track said the belts would take 10 days to arrive. As I waited for the belts, I grew impatient and bough the top belt only from Lowe's, another $32!.
The repair manual says the belts should last for years. As the top belt failed after only 6 months, I have a couple questions. How important is changing both belts?
What could have caused the failure in the first place? The steel core of the failed belt was broken and pulled out for about 1/3 of the belt circumference. the belt appears to have had half its width chewed off.
Last question. The bracket that the idler is on is shown in the manual as having a slot where the pivot bolt is. Does this mean it should be adjusted? Or does this bracket slide in operation? There is no procedure for it that I can find in the repair manual.
The repair manual is dated 2010, so this series machine has been around a while. Someone here must have seen this failure before, and understand what caused it.
Just for giggles, I took a picture of the damaged belt next to a new belt, and added a picture of the idler bracket.





Chuck

That type of belt failure comes from something getting in the path of the belt. Gumballs Cattails sticks sometimes rocks. Check for damage to your v pulley's. Also look for anything lodged inside the pulley. I say this because yours would not be the first. I have first hand knowledge of cattails and gumballs.

BlazNT said:

That type of belt failure comes from something getting in the path of the belt. Gumballs Cattails sticks sometimes rocks. Check for damage to your v pulley's. Also look for anything lodged inside the pulley. I say this because yours would not be the first. I have first hand knowledge of cattails and gumballs.

Click to expand...

Well, I removed the deck and jacked up the front of the Bronco. I got under it to where I could look tings over again. The idler bracket was jammed up against the frame. I loosened the pivot bolt, but it wouldn't still move. So, I proceeded to take off the new belt. I just happened to see the part # on the belt, and kiss my Grits! it's the wrong #!I looked at the pair that arrived yesterday, and there it was, the correct belt! I could probably quote the belt #'s in my sleep, I even wrote them down and put them in my wallet before going to Lowe's to get just the top belt. Must have had a senior moment as I bought the wrong one!

I got the correct belt installed and am now ready to hang the deck. Herself will be happy, as her car will be back in the garage tonight, and she won't have to hear me bitch anymore.

Thanks to everyone that advised, tried to guide me right, pointed to the manuals, and listened to(read) my rants... My sincere apologies, and thanks.

Chuck

Hope all goes well.