Based upon what I see in the machine shop everyday where I am the Director of Quality Control, specialized equipment needs to be used to properly cut external splines. The shaft will have to be removed from the case and taken to a shop who has a gear hobbing machine or a CNC mill. I also see a problem with the center in the end of the shaft. It looks deformed like it has seen some rough treatment. That MAY be a problem if the part is located between centers to perform the work.

Don't take this the wrong way but I hope the original purchase price was expensive - only because that over half you got back may not cover the needed machining.

Also, digital calipers are handy for getting "in the ballpark" measurements, but one really needs a quality set of micrometers.

 

Found this:
Gear box
Might not be correct but might be in the price range of a new drive. You'd still be about $700 to the good.

 

Yes, a new gear box! May be even easier

 

You may have taken the wrong deal. BUT, I would not spend the time/money milling down that shaft unless I had a proper mill...

I would simply get a new shaft and shaft seal from the manufacturer. Don't know how it's assembled, but you probably need split ring pliers and maybe a bearing puller. Do you have the parts diagram?

 

I do believe bigger tractors may have bigger splines.

 

Meh! Dress it with a flat file.

 

It's still brand new, regardless of the purchase price. I'd make a warranty claim and let the manufacturer hook you up with a free replacement gear box.

 

What dimension is too big? Overall diameter or the width of the splines?

 

There are actually several different spline / shaft size standards out there, that all looks similar.
I am curious if the wrong shaft was installed in your unit, but is actually compliant with one of the other standards.

there are adapters out there for this.... here is one example... but you can get M-M, M-F, in both directions... small-->large, or large-->small....
Or you can get a yoke-end for the PTO shaft you have and swap that out, for like $100 or something.... to match the shaft-end on the Tiller

Measure your shaft... is it one of the larger or smaller standards?... or is it a quality control issue, where it's supposed to be size X, but just outside of tolerance by a few thou.

 

There are actually several different spline / shaft size standards out there, that all looks similar.
I am curious if the wrong shaft was installed in your unit, but is actually compliant with one of the other standards.

there are adapters out there for this.... here is one example... but you can get M-M, M-F, in both directions... small-->large, or large-->small....
Or you can get a yoke-end for the PTO shaft you have and swap that out, for like $100 or something.... to match the shaft-end on the Tiller

Measure your shaft... is it one of the larger or smaller standards?... or is it a quality control issue, where it's supposed to be size X, but just outside of tolerance by a few thou.

Thank you so much for that diagram! That is exactly what I needed. The implement stub and PTO shaft are all supposed to be 1 3/8" 6 spline, the shaft is but the stub on the implement is not. Instead of 1.375"/34.95mm they are measuring 1.382"/35.1mm so it looks like a quality control issue!

 

Come to think of it the driveshaft that came with my tiller wouldn't go on the PTO on my tractor. I had to file burrs out of the spline on it.

If it's off a few thousandths I would probably polish it with a flap disc on a grinder.

 

Thanks for all the advice and criticism, I always welcome both. That's how we learn.

The tiller new was $2209.99. The manager returned it and then sold it to me for $1000.00. My refund with tax was $1282.59 back.

I got the calipers and they are likely not the most accurate, and neither are my hands, but after measuring a dozen times on my tractor's PTO stub and the implements stub there is a difference. 1.375" on my JD, and 1.382" on the tiller.

I am going to try to file with a hand file or maybe a die grinder. If I ruin it I will just pick up the replacement gearbox that Bubba18655 posted.

 

Assuming the groove depths are correct a polish swipe on each raised spline with a flap wheel will probably bring it to spec. As is often said "it ain't no rocket ship".

Good deal you got.

 

Assuming the groove depths are correct a polish swipe on each raised spline with a flap wheel will probably bring it to spec. As is often said "it ain't no rocket ship".

Good deal you got.

exactly!

in fact, in europe, the 1-3/8shaft is called out as at 35mm. But the .1mm extra may be what you are fighting

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you can also caliper measure the valleys in the splined shaft. See if the are to-spec. 29.65-29.76mm
and also you can measure the spline-ridge width.

In any case, this is probably a simple fix. I'd do it for a $1000 in my pocket!!!

 

I agree with and would do it, if the splines are the right depth and it is the OD I would hit each flat with a flap wheel or 4" disk. This is not a high speed precision joint by any means.
If your measurement are correct you are looking at less than .010 one pass of a disc will easily take that off.

 

What old machinist said. If it is the actual OD that is too big a flap wheel or filing will work fine. The load is on the sides of the splines. At 540 rpm it truly does not need to be perfect. I would have taken that deal!

 

While you are at it make sure all the mount bolts are tight.

Take the slip clutch completely apart and clean and adjust it. Make sure the provided bolts are long enough for proper adjustment. I had to replace the bolts on my slip clutch with some a 1/4" longer.

Make sure the driveshaft length is correct. If you aren't using a quick hitch it may need some cut off.

Check the gearbox oil levels. I found a 6 inch ruler was perfect to stick the top gearbox on mine. The manual said to have it half full of oil which would be 3 inches.

Your results may vary.

 

i looked up the tiller on the interweb, and it's supposed to come with the PTO shaft.

https://www.tractorsupply.com/tsc/product/countyline-rotary-tiller-5-ft-yellow-rtfk5cl

So was yours shorted?...
did it come with a slip-clutch?... if not - you NEED one.

 

i looked up the tiller on the interweb, and it's supposed to come with the PTO shaft.

https://www.tractorsupply.com/tsc/product/countyline-rotary-tiller-5-ft-yellow-rtfk5cl

So was yours shorted?...
did it come with a slip-clutch?... if not - you NEED one.

It did, both the tractor end and the implement end with he slip clutch are in spec. It is just the Stub on the implement that is out of spec

 

Could you try opening the gap on the pto shaft?

 

Possibly, I'll see if it looks pliable

 

I guess the slip clutch and PTO shaft were not installed on the unit when you got it?

 

No, it comes shrink wrapped with the stand, the feet, the shaft, and the top point of the three point not hooked up. You have to bolt those on then custom cut the shaft.

 

I would try making a warranty claim first before you modify anything. If they had a manufacturing problem that affected a bunch of units, you might luck out and get a new part and not have to monkey around with it. If they won't replace it under warranty, then go ahead and MacGyver it.

 

MacGyver it, that’s hilarious!!! Great advice from Pat too.

 

All the answers have been very good and all would work well. Some might protect him if future issues arise. However for me personally I would have fixed the problem in about the same time it has taken me to reply to this thread a few times. YMMV.