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Well, let me first clarify that I'm not a 420 expert, especially when it comes to the 5-speed trans. I have a 40 (4-speed) that I bought with a broken cluster gear, and I've spent many hours both repairing this and thinking about it. I've also studied both the I&T and JD technical manuals as well as the parts catalogs to determine the path of force through the trans gears. The problem with this cluster gear is that the engine force is always being pushed through it to the PTO if the PTO is engaged, and is also used for 1st and 2nd gear (correction to my earlier post). This means that while brush-hogging in 1st or 2nd gear, the engine, drive train, and PTO are all in sync with each other, all because of this cluster gear. If any one of these suddenly tries to stop (engine sieze, tractor hits tree, brush-hog hits rock) there is all sorts of torque put on this gear, and it's very likely that some teeth are going to let go. I was recently reviewing some 420 info in JR Hobb's book "The Little Giants" and there was a mention that the live PTO option on the 420's was a popular option as it greatly reduced the amount of breakdown in the PTO. Now, thinking about this and looking at the 420 parts manual, this makes sense. With the live PTO, the PTO was no longer driven by coupling to the cluster gear, but by coupling to a new gear introduced for this purpose. This now leaves the cluster gear to serve the drivetrain only, not both the drivetrain and PTO. The load was now spread over more parts in the trans. The five-speed trans w/o live PTO is very similar in design to the four-speed. So I think the answer to your question is that the five-speed trans with live PTO is not necessarily stronger than those four- and five-speeds w/o live PTO, but that it is indeed better suited for brush-hogging. One added note on the non-live-PTO tractors - An overrunning clutch on the PTO will certainly help in the situations where the tractor stops and the brush-hog doesn't. But it won't do any good in the case where the brush-hog stops but the tractor doesn't. You may want to consider adding some sort of shear pin to your PTO drive train. It would be a whole lot cheaper and easier to replace than this cluster gear!
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