Assembly - Toro Reelmaster 5200-D Service Manual

Assembly

Note: Always use new gaskets and Seals when as-
sembling the rear axle.
1. Assemble differential gear case (Fig. 11). Use me-
dium Loctite thread locker on gear case bolts and tight-
en evenly to 20 to 24 ft-lbs (27 to 33 Nm).
2. Assemble pinion gear and pinion gear case (Fig. 11).
Tighten pinion nut to pre-load bearings. Pinion gear
should require 2 to 5.5 in-lbs (0.23 to 0.62 Nm) torque
to rotate. Once correct pre-load is set, bend tabs of lock
washer and install oil seal.
3. Adjust pinion gear to ring gear engagement (see
"Pinion Gear to Ring Gear Engagement" in this section
of this manual).
4. Adjust pinion gear to ring gear backlash (see "Pinion
Gear to Ring Gear Engagement" in this section of this
manual). Backlash can be checked by removing the dif-
ferential inspection cover (Fig. 11).
PINION GEAR TO RING GEAR BACKLASH:
0.003 to 0.010 in. (0.08 to 0.25 mm)
5. Tighten pinion gear case bolts to 16 to 20 ft-lbs (22
to 27 Nm).
4WD Rear Axle
(Unit Serial No. 80001 - 99999)
6. Install knuckle pin, needle bearing, washer, spacer,
and inner bevel gear in gearbox housing (Fig. 12). Install
bearing and bearing retainer to gearbox housing and
tighten bolts evenly to 6 to 8 ft-lbs (8 to 11 Nm).
7. Align gearbox housing, knuckle housing, and
knuckle arm. Install knuckle arm bolts (Fig. 12).
8. Install outer bevel gear and knuckle cover to knuckle
housing (Fig. 12). Use medium strength Loctite thread
locker and evenly tighten the cover bolts to 12 to 20 ft-lbs
(16 to 27 Nm).
9. Assemble outer axle shaft and bevel gear to knuckle
cover (Fig. 12). Use medium strength Loctite thread
locker and evenly tighten the cover bolts to 12 to 20 ft-lbs
(16 to 27 Nm).
Note: The top two (2) bolts used to attach the outer
axle shaft knuckle cover are shorter than the remainder
of the cover bolts.
10.Assemble axles and axle tubes to gearbox housings.
11. Install axles and axle tubes to differential housing.
12.Install axle assembly (see 4WD Rear Axle Installa-
tion in this section of this manual).
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Rev. A
Reelmaster 5200-D/5400-D