Toro Reelmaster 5500-D Service Manual page 185

8. Install the outer pinion spacer with the chamfer to-
wards the pinion splines and position the new outer
bearing cone on the pinion shaft (Fig. 31).
9. With a hollow press sleeve of proper diameter, press
on the outer bearing cone race until the drive pinion
seats in the carrier and a slight drag is felt when the gear
is rotated by hand (Fig. 32). If more than 2-13 in-lb.
(.2-1.5 Nm) torque is required to rotate the pinion and
spur gear, tap the pinion shaft with a soft mallet until the
drag is reduced.
10.Install differential gear holder to carrier to retain spur
gear (see Special Tools). Apply Permatex No. 2 (or
equivalent) to outer diameter of seal, external splines of
pinion shaft and internal splines of pinion coupler.
11. Install seal into housing. Install the shim, pinion cou-
pler, spacer, and nut onto the end of the pinion shaft.
Tighten pinion coupler nut to a torque of 75−90 ft-lbs
(100−122 Nm). Remove differential gear holder and
check pinion shaft endplay. If necessary, change shim
to adjust pinion shaft endplay.
PINION SHAFT END PLAY:
0.000 to 0.005 in. (0.00 to 0.13 mm)
Note: Pinion shaft shims are available in 0.094 in.
(2.39 mm) to 0.120 in. (3.05 mm) thickness, and in
0.125 in. (3.18 mm) to 0.151 in. (3.84 mm) thickness in
0.002 (0.05 mm) increments.
12.Install the spur gear cover. Use Permatex No. 2 or sil-
icone sealant when installing the cover. Tighten the
capscrews to a torque of 25-40 in.-lb. (3-4.5 Nm)
(Fig. 33).
Reelmaster 5500-D Page 6 - 15
Rev. D
Figure 31
Figure 32
Figure 33
Differential Axle