Toro Groundsmaster 455-D Service Manual page 195

Transaxle Disassembly
1. Clean all exterior surfaces of transaxle.
2. Put the transaxle on a work bench with cover side up.
Remove screws. Lift cover (Fig. 20, Item 16) off and
discard gasket (Item 4).
3. Remove differential assembly and thrust washers
(Item 8A and 9).
4. Remove large drive gear (Item 18) from input shaft
bevel gear assembly.
5. Before removing shifter rod and fork, the bolt
(Item 22), spring (Item 24) and ball (Item 23) should be
removed at the outside of the case.
6. Remove shifting rod (Item 36), fork (Item 35) and
shifter gears (Item 19).
7. Remove output shaft assembly.
8. Remove shifter / brake shaft assembly.
Inspection
1. Check case and cover for leaks or cracks.
2. Remove and discard all oil seals. Do not replace seals
until unit is reassembled.
3. Inspect needle bearings and replace if necessary.
Use an arbor press and properly sized tool to remove
and install needle bearings. When installing bear ­
ings, apply pressure to bearing from stamped side.
Bearings should be pressed in 0.015 to 0.020 in.
below the thrust surface.
4. Check gear teeth for wear, pitting or breakage.
5. Inspect bearing surfaces for smoothness.
6. Inspect gears and shafts for out of round.
7. Splines should allow a smooth fit. Rotate meshing
parts for a better fit if binding seems excessive.
8. Check shift detent spring for tension and ball for wear.
9. Check shifter rod grooves for wear. Be sure snap ring
sharp edges go away from shifter fork.
10. Inspect shifter fork for straightness and wear.
11. Check differential for loose or damaged parts.
12. Check differential carrier ball bearings for wear and
smoothness of rotation and replace if necessary.
®
Groundsmaster 455-D
Transaxle Assembly
Reverse steps 1 - 8 under Transaxle Disassembly,
watching out for the following:
1. After shift rod is in position, install ball, then spring
and bolt. Turn bolt in until head of bolt contacts case.
2. Be sure that thrust washers and spacers are between
every shaft and case and cover.
3. Threads of differential bolts must be coated with
standard stud Loctite. Install differential assembly so
bolt heads are facing away from gear on output shaft.
4. Install new gasket. It may be helpful to dampen gasket
with oil to get it to lie flat.
5. After installing cover, install new brake shaft oil seal
(Item 51), shifter rod oil seal (Item 25) and axle shaft oil
seals (Item 7).
6. To install axle assemblies into transaxle case, grease
axle spline ends heavily. Push axle through seal. Use
caution to prevent damage to seal when axle splines are
going through seal.
6. Install hi/low interlock switch (Fig. 17, Item 17) into
transaxle case if removed.
Thrust Washer
Page 6 - 13
Figure 21
Thrust Washers
Thrust Bearing
Shims
Figure 22
Repairs