Toro 4100-D service manual Differential Gear Installation

Differential Gear Installation

1.If the ring gear was removed, use medium strength thread locking compound and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N--m).

2.Apply molybdenum disulfide grease to the splines and bearing surfaces of the differential pinion gears, pin- ion washers and side gears.

3.Install the side gear shims and side gears in their original location in the differential case.

4.Place the differential pinion gears and pinion wash- ers in their original location in the differential case. Tem- porarily install the differential pinion shaft.

5.Secure the differential case in a vise. Position a dial indicator at the tooths center and measure the differen- tial pinion gear to side gear backlash (Fig. 39).

PINION GEAR TO SIDE GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm)

6.Adjust backlash by increasing or reducing side gear shim thickness.

NOTE: Side gear shims are available in 0.043 in. (1.1 mm), 0.047 in. (1.2 mm) and 0.051 in. (1.3 mm) thick- ness.

7.Apply gear marking compound, such as DyKemR Steel Blue lightly over several gear teeth.

8.While applying a light load to either side gear, rotate either pinion gear until the side gears have made one complete revolution.

9.Ideal tooth contact should cover more than 35% of each tooth surface. The contact area should be in the center of each tooth and extend 1/3 to 1/2 way across each tooth from the toe (small) end (Fig. 40).

10.Adjust side gear shims if necessary to correct tooth contact. Recheck differential pinion gear to side gear backlash if any changes are made.

11.After backlash and tooth contact have been ad- justed, align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin.

3

2

1

		Figure 39
1.	Vise	3. Dial indicator
2.	Differential gear case

More than 35% total tooth contact

1/3 to 1/2 of entire width from small end of tooth

Figure 40

12.Install differential gear assembly in right side axle support half.

13.Coat a new O-ring with grease and install left side axle support half. Tighten axle support case screws from 35 to 41 ft-lb (47 to 56 N--m).

14.Install input shaft/pinion gear assembly (see Input shaft/Pinion in this section of this manual).

15.Coat new O-rings with grease, align differential shaft splines with differential gear assembly and slide differ- ential shaft assemblies onto axle support.

16.Install bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).

Axles, Planetaries and Brakes Page 6 -- 28 Groundsmaster 4100--D