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Hats off to Dumb Luck for taking the time to post this video. I used the vice method mention below to squeeze the plugs/inner gear into the housing. I found this video while searching for info on how to install a replacement assembly including the motor, arm and bracket that I previously purchased. After discovering rivets would need to be drilled out to replace the existing assembly I decided to purchase the Dorman plugs. Again thanks to Dumb Luck for posting this video!

I need to do this to my 95. All I've seen are stake pocket options, but mine are covered by the tonneau rails.

You are correct. Sorry for not mentioning the notch. It's been so long since I did this project, I can't recall if there was a slot for the notch to fit into. I don't think there was because you'd think that would be sufficient to keep the fan from spinning loosely on the shaft.

Thanks for taking the time to make this. A little long - but very realistic! Thanks! We did a 'sorta' repair (not with actual gears plugs) that only worked for about a year - now I think I can do the repair since the holes are already drilled out. I saw several repairs using nuts but I worry that it would negate the safety feature and with my luck it would be my finger that gets pinched! As an aside, while I had the door panel off, went ahead and replaced the door sweeps to (my 95's were dry and cracked). Good point about checking the drain holes.

Look at the center of the fan there is a notch that goes on the crankshaft you did not mention.

It costs a little more to have a pre-spooled line, but when you're in the middle of a trimming job th-cam.com/users/postUgkx429xwEjNPnwzQohFrURRyKF51YfOD_Du , it is so nice to just pop out the old one and pop in a new one. Love Black & Decker tools. Especially the 20-volt battery operated ones. And, as usual, it came on time. Thanks Amazon!

You forgot to tell us what type of replacement washer and where to buy it please ?

Well done! 😎

I replaced the star lock washer with a different type of star washer. There are two kinds of star locking washers one that has the smooth side in and the ones like Craftsman should have used that have the star locking part inside. The reason their type fails is that the locking part is uncovered making it work like a plain washer instead of a lock-washer.

Where can i get a cooling fan assy., to fit a Tb 685ec 4-stroke trimmer?

I have the same trimmer. The pull start sucks and I went with the drill adapter to start it. One day I was trimming and BOOM engine stops abruptly. The fan broke in a few places and cut into the oil fill tube. I tried running without the fan, engine gets very hot and smokes. As others have said part#753-08503 is the cheapest way to get a fan, but you have to get oil pan assemble with it. Troy Bilt needs to give the fans out for FREE!!!

I have a 1992 F-150 5.0 extended cab that had the disintegrating window motor gear plugs issue. I initially had the same difficulties trying to assemble the plastic gear, plugs, and metal gear, but found a way to assemble them where no modification to the plugs is needed. My method is counterintuitive, but worked perfectly the first time I tried it. Rather than placing the plugs in the plastic gear, and trying to press the metal gear into the assembly, I greased the plugs to give them some stiction, set them into the recesses in the metal gear, set the plastic gear over the plugs, and compressed the assembly together in a vice. Like I said, worked perfectly the first time. Prior to doing that, I had placed the plugs into the plastic gear, and tried to fit the metal gear in between the plugs with no luck. I must have fiddled around with that method for about 20 minutes before trying my alternate method. I purchased a Dorman 747-409 gear & plug kit, but found that the gear that came with the kit was too large in diameter to fit in my window motor housing. I think the problem was that the kit is for a 5/1/1992 and up, and my F-150 must have been manufactured prior to that. No, worries, I was mainly after the widow motor gear plugs, but figured I might as well replace the plastic gear while I had access.

Is this the incredi-pull models?

Hi what length and diameter is the pull cord? thanks

I love it when the end user is smarter and more honest than the manufacturer!!!

Talk about 'dumb luck', I never thought I'd find anything on you tube with this problem but there you are. Good video thanks a ton!!!

Yeah but you didnt repair the pull start. Wasnt that the title of the video?

All Craftsmen are designed to fail. Mine is 2 years old and probably has less than 20 hours. Doesn't want to start. Then when it does, you can't give it throttle. It stalls. JUNK!

so did you use a split lock washer with the star washer and maybe some thread locker .I have the same trimmer and my start adapter that holds the fan on keeps coming loose .what worked for you. Thanks great video

How do you take the cover off to get to the fan and spring

You did not show the most important step. Replacement process of the washer ? What washer was used ?

Great video! Can you provide the information for new washer that you used to repair the failed washer?

*I have used Stihl for over 20 years 🌴 **allabout.wiki/Troy** and after reading some reviews of this trimmer, I tried Troy-Bilt , and I'm going to switch. Compared to several Stihl trimmers I've had, this one is easier to start, quieter, and feels at least as well built . A major plus is it doesn't have the wonky, always leaking, complicated gas tank caps that Stihl has.*

I have a Troy built model TB 6044XP. Has had very little use mainly because it’s always broken. Had the pull start repaired once and is now broken a second time. I will never buy anything Troy built again it’s junk.

Hi Good info but many will want to see what you did from start to finish. It makes the video much better and helps people truly. Otherwise good video

do you know where i can buy the fan? or what is the part #

YOU HAVE TO WELD TRIANGULAR GUSSETS IN THE BACK OF THE FAN TO FIX THIS. IF IT HAS A STRESS CRACK, MODIFY A NEW ONE WITH ADDITIONAL SUPPORT, OR STRAIGHTEN FAN AND DOGS FIRST, THEN TIG OR MIG WELD PLATES ON BACK. TEST FIT FIRST AND HOLD GUSSETS IN PLACE WITH LOCKING PLIERS OR C-CLAMPS BEFORE YOU DRAW A WELD BEAD.FOLLOW EASY PULL INSTRUCTIONS BELOW ON THIS POST. YOU CAN USE THE OLD FAN, CUT UP 1/3 DIAMETER TRIANGLES AS THE GUSSETS, TAKE THE BLADES OFF THE GUSSET BLANKS.

Same works for craftsman weedwacker 17 25cc

Thanks for the video. How do you replace the springs on that spindle

Do you know where I could find a replacement fan with springs for my TB6044XP

Some words of advice. I bought a used TB685EC, starter did not work. Pulled off the starter and discovered the problem, damaged pawl mounts on the fan blade. The damage was likely caused by the owner just jerking the starter rope. Do not just jerk the starter. Slowly pull the starter rope until the starter engages, then give the rope a good pull. Jerking the rope forcefully without carefully engaging the starter first is asking for trouble. This is a common problem with many starters, even on small outboard motors, I've seen it a lot. Do not just jerk the rope and you will lessen the likelyhood of damaging the already junky starter.

Bought mine and didn’t have it a year and it started this, now it won’t even let me jump start it. First time buying Troybilt and last time too.

Is the fan supposed to catch the plastic housing of the pull cord? I fixed the tension of my pull cord, but it won't start. It's definitely not catching something. 🤔

the fan broke on my 8044 trimmer.... can i just get the fan.. MTD is telling me i need to order the short block for $80 + .. what if i eliminate the fan? does it really matter?

Pull start and fan busted twice. Junk model

that allen is actually a # T-8 torx

Ingenious solution to an unfortunate engineering flaw! Nice job.

Mine is leaking oil through the air filter. Any ideas? TB6040 XP. Thanks.

I am having trouble getting the cover off. An oversight in the process. Looking into the hole where the screw is it seems to be a round specialty kind of screw head.?

Is that model electric start capable?

Anywhere I can reorder the fan? Mine completely broke beyond repair?

It works! cost only 2 pennies, thank you very much Sir!

Same issue exactly. Criminal not to offer replacement parts. Also need spring

Thank you for posting! this is a shame Sears put this cheap washer in such an important role on this piece of equipment

I'm going to crosspost this to the other repair video as well, it's long but please read: I got one of these by sheer dumb (bad?) luck. I had already bought a few of the 27cc full crank Craftsman branded MTD 27cc 2 stroke trimmers, the one with no choke. They instead have a solenoid on the carburetor that is powered by the magneto ignition coil and often if primed correctly and using non-ethanol fuel will start and stay running on the very first pull even after being stored all winter. I got them from a now defunct fleaBay seller that sold store returns, taddwholesale. They screwed up and sent me one of these instead one of the times. Mine is a 2013 model that came without the recoil start assembly even being present and with the plastic pawls already broken. I had been using mine sans the recoil, IE just a bare spinning fan, until the thing killed the one way sprag clutch in the drill start bit and then the drill itself. Now my thoughts as to the issues as observed on mine: Obviously the whole cheap plastic cantilevered pawl on a stamped sheet metal fan disk thing that they pass off as a starter assembly is junk, but somehow it isn't the problem here since the same pawls in a stamped steel cup work fine on the 2 smoke. The problem is at least twofold. First this is not, I repeat, IS NOT a full crank trimmer despite having the starter on the back. The shaft coming out of the sump is not the crankshaft. If you remove the plastic oil filler assembly or the whole sump and look inside you will see that that fan and stub shaft assembly has a drilled metal counterweight that just slips over the crankpin next to the connecting rod on what is otherwise a run-of-the-mill half/cantilever crankshaft engine. I haven't removed the sump on mine because I don't want to wreck the gasket but if I did I'm sure it would come right off without removing the fan first. If this were a full crankshaft trimmer this wouldn't be possible. As a result of this the stub shaft that the fan is on has inadequate support bearings and so has some radial and rocking play to it that wouldn't exist if it were actually part of the crankshaft. The second is that the engine has lots of compression, no compression release mechanism, at least nothing ever blipped one of the valves when I turned it by hand while measuring the valve lash, and being a handheld trimmer that they were trying to make as light as possible it doesn't have nearly enough flywheel inertia/weight to help get it past TDC compression without excessive strain on the start components. To minimize the strain on them here is what I would do each time instead of just blindly yanking on the rope. Try to avoid fully winding up and binding the "Incredipull" start assist spring when the engine hits compression to minimize the strain on the pawls. Since I don't have the recoil for mine I have no further idea on how to actually accomplish this. For the cordless drill start bit use a multi-speed gearbox drill set to the highest speed/lowest torque/reduction. This is how I broke my bit and drill, I used a single speed drill that turned too slow and the inertia of the motor and geartrain trying to supplement the lack of inertia of the engine's flywheel sent too much peak torque through the bit and broke both. When starting engage the start bit to the engine and either turn the engine by hand, by carefully gently squeezing the drill trigger, or pull the recoil slowly until just passed compression then pull the drill trigger as suddenly and fully as possible to try to build as much speed as you can before it hits the next compression stroke. I suppose that this would also apply when using the standalone Craftsman Speed Start AKA Troy-Bilt JumpStart starter unit. I hope that this helps anyone who already has one of these trimmers.

Great vid , going to give it try !thanks .....👍

those starter pawls will be next....

I have this model and the pull cord won’t engage the pawls on the fan blade. Fan blade turns the shaft fine, but I can’t figure out why the plastic solid tabs on the back of the pull starter won’t lock with the pawls and turn the fan. Has anyone else had this issue? Pawls and their springs look fine.

I just purchased the new version of the weed trimmer. I wish I had seen this video first and it would have save me all my grief. This piece of Shxx is not worth $200 buck and it does not start. It is going back today

How do you get the shaft off, I've tried everything.