Toro REELMASTER 4500-D, Service Manual

Page: 284 / 302

Disassembly of the Planetary Wheel Drive
1. Slide the coupling (1) from splines on input shaft (2).
2. Position the assembly upright on face of spindle (3).
3. Remove the disengage cover (18).
4. Remove bolts (17) and large cover (19). The disen-
gage plunger (22) usually remains with cover. Remove
plunger and O–ring from cover on end of input shaft.
5. A thrust washer (23) will usually remain in position on
thrust face of cover.
6. Remove primary sun gear (13) and thrust washer (12)
from end of input shaft.
7. Remove primary carrier assembly (15).
8. Remove the secondary carrier assembly (20). It may
be necessary to remove the ring gear (24) first, if difficul-
ty is encountered in removing the carrier.
9. Remove input shaft (2) from spindle (3). Remove the
retaining rings, washers, and spring from input shaft
only if replacement is required.
10. Remove the 6 or 12 bolts from hub and ring gear and
remove ring gear (24). It may be necessary to strike ring
gear with a rubber mallet to loosen from hub.
11. Remove the large retaining ring (28) from in front of
the tapered bearing and lift hub (8) from spindle. If bear-
ings are not a loose fit, it may be necessary to press
spindle from hub.
NOTE: Use a snap ring expander tool to remove retain-
ing ring.
12. Remove the oil seal (4) and bearing cones (5 & 9)
from hub. Inspect bearing cups (6) in position and re-
move only if replacement is required.
Assembly of the Planetary Wheel Drive
1. Press a new bearing cup (6) in each side of the hub
(8).
2. Assemble a bearing cone (5) into cup (6) at seal end
of hub and press a new oil seal (4) into hub.
3. Position spindle (3) upright on bench. Lubricate lips
of oil seal (4) and lower hub onto spindle. Hub (8) should
be centered as it is lowered over spindle to prevent seal
damage.
4. Assemble bearing cone (9) over spindle and into
bearing cup (6). Select the thickest retaining ring (28)
that can be assembled into ring grooves of spindle shaft
above bearing cone. Bearing should have from
.000–.006 inches (.00–.15mm) end play when proper
retaining ring is installed.
5. Assemble a retaining ring (25) in groove opposite pi-
lot end of input shaft (2). Assemble a washer (26),
spring (27), a second washer (26), a second retaining
ring (25), and a third retaining ring (29) in the middle
groove of input shaft. Some shafts have a shoulder and
require only one retaining ring.
6. Assemble the splined end of the input shaft down into
spindle.
7. Assemble secondary carrier splines over splined end
of spindle.
8. Apply a bead of RTV compound to hub face that
mates with ring gear (24)*. Assemble the end of ring
gear having 6 or 12 bolt holes against hub with bolt holes
of hub and ring gear aligned. Assemble the six
3/8–24x1–7/8 inch hex head bolts. Torque bolts to
39–49 (52.9–66.4 Nm) pound feet. If grade 8 bolts are
used, the bolts should be torqued to 52–60 (70.5–81.3
Nm) pound feet. Grade 8 bolts can be identified by the
6 radial lines on bolt head.
9. Assemble the primary carrier and sun gear into ring
gear. It will be necessary to rotate carrier and pinion to
align sun gear teeth with secondary pinion and primary
pinions with ring gear teeth. Assemble the primary sun
gear (13) over input shaft. Rotate sun gear to align shaft
to gear splines and gear teeth.
10. Assemble the small thrust washer (12) over input
shaft and against shoulder of shaft.
11. Assemble an O–ring (21) in groove of the disengage
plunger (22). Assemble plunger over end of input shaft
and against thrust washer.
12. Lubricate the O–ring in groove of engage plunger.
Assemble the thrust washer (23) with tangs engaged
with large cover (19). Apply a bead of RTV compound
to end face of ring gear.* Assemble cover over plunger
as holes of cover and ring gear are aligned. Assemble
the eight 5/16–18x1 inch hex head bolts. Torque bolts
to 20–25 (27.1–33.9 Nm) pound feet.
13. Assemble the disengage cover (18) with dimpled
center protruding out if wheel is to be used to drive the
vehicle. Assemble and torque the two 5/16–18x3/4 inch
bolts. Torque bolts to 10–20 (13.6–27.1 Nm) pound feet.
14. Invert the Power Wheel assembly and assemble the
coupling (1) with counterbore out to the input shaft.
Axles and Brakes
Page 6 – 8
Reelmaster 4500–D