Marshall - I have a One-Eighty with a manual PTO and I had the same issue. You probably have one or two problems, one with the rear PTO shaft and possibly one with the linkage.
I'll start with the rear PTO shaft and I learned this from Dr. Allis. On a manual PTO you engage it by sliding a splined coupler that sits on the front PTO shaft into engagement splines on the rear PTO shaft. Over time with use, the rear PTO shaft splines get bunged up and have burrs on them preventing engagement. You'll need to remove the rear PTO shaft to take care of it. First drain both the torque tube/PD/Hydraulic compartment AND also drain the rear transmission/differential. Remove the 3 bolts holding the rear PTO bearing carrier & seal. Give the rear PTO shaft a firm yank straight out the back. You are pulling it out through two seals between the torque tube and transmission so pull it straight so you don't catch and tear the seals. Once you get it out it'll look something like this:
You'll need to grind down the burrs. I find that a dremel tool with a small grinding wheel is perfect. Dress up all the burrs so the splines can go into the coupler again easily. Even if fairly rough looking you can dress it up and put it back in and it should work fine. While you have it our, might as well check the rear bearing and definitely replace the rear seal and big o-ring. Take the same care in putting the PTO shaft back when you reinstall it when you push through two seals between the cases. Before you fefill your fluids check to see if the engagement works. If not, you might need to pull it back out and dress up the splines some more.
Now, if you still have issues it might be with the linkage and the control arm coming out the left side of the torque tube near the clutch pedal pivot. My control arm got bent by the prior owner by pushing the lever too hard when the PTO would not engage from the spline burrs. So even when the PTO shaft was fixed the linkage would not move the sliding coupler to fully engage the PTO. To get it at it I had to remove the battery box and clutch pedal. I had to bend my control arm back using a crowbar (notice the nicks on it, lol). He's what it looks like after I bent it back:
Here's a pic with the linkage hooked back up and the clutch pedal back on:
A few more pics are here in Photobucket:
http://s39.photobucket.com/albums/e176/Skyhighballoon/One%20Eighty%20PTO/Let us know if this help and you get it fixed or if you have any more questions. Mike
Edited by Skyhighballoon(MO) - 25 Jul 2010 at 10:44pm
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