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Ive got a new 825i. I use it for work quite often, 1600 miles and Im on the 3rd drive belt. The problem now is its a bear to shift. You have to pretty much force it into gear and then when you take off it will jump out of gear. Then you have to come to a complete stop and put it back in and then hope for the best. Any ideas?
 

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It could be a cable adjustment issue, but we see a lot of primary clutches not releasing back to the stops. The primary clutch will grab the belt ever so slightly and load the transmission clutch causing a hard shift condition. I would remove the top belt cover, get some penetrating oil or a VERY small amount of tacky grease that is waterproof and apply onto the weight rods, rollers, outside collar shaft. Start engine and rev WOT then idle a few times to work the lubricant into the clutch components. That usually works here. Maybe the transmission won't need some synchro work after this is performed.
 

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We had the similar problem here recently on a 620i. Come to find out one of the small bolts in the primary was gone. How that came out is a mystery to me.
 

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Its completly damaged. If my guys have not thrown the parts out, you can have it. Looks like they busted one of the cups, ball bearings are gone. And they welded onto the end of the shaft to pull it out.
 

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Just wondering if anybody else is having this same issue? I am having a hell of a time going from forward to reverse, very, very hard to shift and also going forward it keeps popping into neutral. Any suggestions would be fantastic. I looked at the little u-bolt thing connected to the shifter under the box, but to me it doesn't look like there is much adjustment to it.
 

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I have a 2013 Gator 825i. I have 65 hours and 153 miles on it. It will not shift into, or out of gear. The dealer is telling me the clutch is burnt out and I need a new one, ($318.00 for parts and 1.5 hours labor) I have babied this thing since the day I got it. Has anyone talked to a JD rep about this ? My dealership is NOT standing beside me and I'm going to make a trade deal with Polaris? and give them a free commercial telling them what a POS this company is if someone doesn't do something.
 

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Well i am sure that the dealership is doing what they can but i am guessing you are out of Warranty. Just because something fails outside of a warranty doesnt mean the company is a POS. Do you think Polaris would be any better outside of warranty? I could understand if you were having issues two months after your purchase but seems like you are getting a little angry for something that just happens.
 

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Yes, I am out of Warranty, by 6 months. After reading comments on here about hard shifting, defective clutch assemblies and replacing drive belts, I believe there is a common related problem. If a person has to replace the clutch assembly every 65 hours, then there is obviously a something defective somewhere. I didn't pay $13,000.00+ to have replace parts every 65 hours,.............. any parts ! My other 2 gators I drove over 3,000 hours each, and NEVER had a clutch problem or any major repair. If JD won't admit it, then they'll lose this customer, and as many as I can convince about their product.
 

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New update on my clutch problem, JD is paying for the clutch and I paid the labor to have it replaced. Apparently there IS a problem with the clutch "sticking" and JD admitted it. They said the tolerances are so close that when the clutch heats up, it sticks to the drive belt under torque and will not release. It definitely explains why they get so many "hard to shift" complaints. The older 550's did the same thing and JD replaced about 50% of all the ones sold. They have no 'fix' for it except to replace the clutch and/or the drive belt. Thank you John Deere for helping take care of my problem. My 825i is awesome in every way except for this defect.
 

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Like many of You folks, I too have had my problems with the 2014 825I-S4, Its been doing fine after the motor and front diff were replaced.. Yet mine to has "poped out" of gear about three times, Someone on here had warned me the trany would go out next. I know there are clutch issues as the local Deere service man had told me that he had been replacing some... I agree seems to be a problem here that shouldn't be happening. GM had a problem that there sure fighting now that should have been took care of early on.. Deere is a long standing solid company they must get on this in my opinion.. I full time farm and I do it with mostly Deere equipment, I'm a loyal customer. But my present Gator worries me every time i use it..
 

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Go to your dealer and have them look up solution number 96997, which talks about transmission popping out of gear on these models. It calls for possibly replacing the shift collar and high gear splines in the trany.
 

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I should ask that next trip to town as it jumped out of "R" today after I posted to this thread this morning.. Thanks for the good info..
 

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Is there any chance that this clutch is not disenguaging due to hight idle RPM or a jammed flyweight or something....if its enguaged and putting pressure on the belt (trying to roll the belt) I could see that causing issues with enguaging the transmission....just a thought...
 

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Hmmm, My 2011 with <125 miles on it has also slowly become hard to shift from D-N AND R-N. I have to actually shut off the engine to shift it into N? Forcing it while the engine is running is going to eventually break something not to mention deform the linkage. Its not the cable, maybe its staying loaded somehow or its a more serious internal trans fault. Regardless my lil Gator does seem to have had its share of problems.
 

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Ok...I'm not an expert in this one...But if shutting off the engine allows it to shift into gear....I really believe that the belt is pulling....It’s a pain to do...but I would pull off that cover and check that clutch....Maybe that idler/roller is seized up (on primary) causing drag. Remember that the belt is the only connection between the engine e and transmission....Are the clutch sheves squeezing the belt at idle....???
 

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I agree, some degree of load/rotation is still applied while in neutral and it is most probably a clutch not totally disengaging. I will pull the covers and take a look.
 

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There were/are several trans/clutch related problems in the 825i and the XUV 550. Proper diagnosis is the key to a one stop repair. Unfortunately the root cause is missed by the technicians and parts are launched in hopes of fixing the REAL problem. Then the customer gets pizzed, the service mgr gets pizzed.. tech is pizzed. Not good.
I've worked with the Deere guys since day one on the problems with the 825i and XUV550. Sent ALOT of parts back for review, Took many pics and wrote alot of text on how to solve their issues.
The fact that Deere will stand behind an out of warranty machine says volumes about the product. Try that with the others and see how far ya get.
 

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Companies that want to improve quality listen to mechanics that provide feedback. They are on the front lines and see issues that the engineers have not seen or imagined. It can be variables like manufacturing variation or just usage is not as expected.

Quality is a continual process...it is not an end since there are always changes going on.

From the feedback here, JD actually does listen and often willing to cover some repair expenses for post-warranty.
 
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