Toro Groundsmaster 4100-D Service Manual page 216

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. 37).
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. 38).
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.
Axles, Planetaries, and Brakes
2
1
1. Vise
2. Differential gear case
More than 35% total tooth contact
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).
Page 6 − 26 Rev. C
3
Figure 37
3. Dial indicator
1/3 to 1/2 of entire width
from small end of tooth
Figure 38
Groundsmaster 4100−D