Installation Instructions

ManualsBrandsToro ManualsWalk-Behind MowersReplacement Gearbox Cover and Seal Kit, Greensmaster Flex 18 and Flex 21 Mower

FormNo.3362-499RevA

ReplacementGearboxCoverandSealKit

GreensmasterFlex18andFlex21Mower

ModelNo.117–1461

InstallationInstructions

Installation

RequiredTools

•Impactgun(3/8inchdrive)

•Cordlessdrill(3/8inchdrive)

•Quickconnectadaptorforcordlessdrill

•Quickconnectto3/8driveadaptor

•6inchdrillquickconnectextension(drillholesin

seals)

•5/32drillbit-Quickconnectoralternative(holes

inseals)

•25lb.springscale(check/setcabletensions)

•K-LineTOR6005SealRemovalTool(removeold

seals-willrequirea1/2inchdrill)or3each#12x2

inchsheetmetalscrewsw5/16inchhead

•K-LineTOR6009SealInstallationTool(toinstall

newseals)

•3/8inchdriveratchet

•0-200in./lb.Torquewrench

•12inch(minimum)Adjustablewrench-2each

•8inchneedlenosepliers

•FlatMillle

•Plasticheadhammer(asrequired)

•Prybar(aidingearcaseseparation)

•Snapringpliers(large)

•SAEhexkeyset

•3/16bladescrewdriver(clipremoval)

•3inch3/8driveextension

•6inch3/8driveextension

•18mmsocket(axlenutremoval)

•18mmcombinationwrenches-2each(breaktorque

onaxlepulley)

•13mmratchetwrenchwithswivel(gearbox

attachmentnuts)

•13mm3/8drivesocket(cover&hardwareremoval)

•8mmhexwrench(oilllplug-new)

•5mmhexon3/8drive(gearboxcoverscrews)

•1/2inchcombinationwrenches–2each(cable

removal/adjustment)

•5/16inchsocket3/8inchdrive-Quickconnect

(insertsheetmetalscrews)or

•1/8inchHexwrenchorscrewdriver(angette

bearingsetscrews)

•3/4inchcombinationwrench(nutsonTOR6009)

oradjustablewrench

•1inchcombinationwrench(ventadapter)or

adjustablewrench

•1–1/4inchcombinationwrench(TOR6009)or

adjustablewrench

•OilresistantRTVadhesive(asneeded)

•94ouncesofDexronIIIATFFluid

•Oildrainpan

•Smallfunnel

1.Positionthemachineonasuitableworksurfaceand

removethesparkplugwirefromthesparkplug.

2.DrainanddisposeoftheATFuidinthegearbox.

RefertotheOperator’sManualorServiceManual

fortheprocedure.Retainthedrainplugandllplug

forusewiththenewgearcasehalf.

3.Youcanremovetherightandleftaxleshaftsealsat

thispoint,priortotheremovalofthegearboxfrom

theframeoronceitisremoved-whichevermethod

youndeasiestwillwork.Takecarenottodamage

theboreortheoutsideedgefaceofthebore.If

eitherofthesesurfacesisdamaged,removeany

burrsandinstallthesealswithabeadofoilresistant

RTVorequivalentorreplacethecasehalf.

Note:Itisrecommendedthattheshortshaft(right)

sidedifferentialaxlesealandsnapringberemoved

toalloweasyremovalofthegearcasecoverinStep

10.Thisoperationcanbeperformedatthispoint

whilethegearcaseisstillinstalledinthemachineor

afterStep8.Eithermethodwillwork.UseK-Line

ToolTOR6005toremovetheseals,orusesheet

metalscrewstoprythesealoutofthebore.Take

carenottodamagetheleftsideinsidediameterseal

bore.Ifthissurfacebecomesdamaged,removeany

burrsandloosealuminumfragmentsandinstallthe

newsealwithasmallamountofoilresistantRTVor

equivalentonlyiftheinsidediameterofthisbore

isdamaged.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

Summary of content (8 pages)

PAGE 1
Form No. 3362-499 Rev A Replacement Gearbox Cover and Seal Kit Greensmaster Flex 18 and Flex 21 Mower Model No. 117–1461 Installation Instructions Installation Required Tools • Impact gun (3/8 inch drive) • Cordless drill (3/8 inch drive) • Quick connect adaptor for cordless drill • Quick connect to 3/8 drive adaptor • 6 inch drill quick connect extension (drill holes in seals) • 5/32 drill bit - Quick connect or alternative (holes in seals) • 25 lb.
PAGE 2
4. Mark the position of the brake, reel and traction control cable jam nuts located at the gearbox ends of these cables. The positions can be marked with either a felt tip pen or paint pen marker. This will enable more accurate reinstallation of the cables at the conclusion of the installation. Loosen the one side of the jam nut assembly to remove the cables from the gear case housing locations.
PAGE 3
4 If the sleeve is dislodged please press it back into position and release any internal pressure before the seal is pressed into the gearbox bore. After the seal is pressed into the gearbox bore, but before the installation tool is removed, there should be a dwell time with load applied to the seal face and shell. Dwell time should be from four to six seconds before removal of the installation tool.
PAGE 4
B. Remove the check plug from the right-hand side of the transmission (Figure 3). Maintenance C. Remove the fill plug, from the top of the transmission, and add enough Dexron III rated ATF lubricant until the level reaches the bottom of the check hole. Checking the Transmission Fluid Level Service Interval: Every 50 hours D. Install the plugs. The transmission is filled at the factory with approximately 94 fluid ounces of Mobil Dexron lll automatic transmission fluid.
PAGE 5
When the transmission is warm, the transmission fluid is hot and under pressure. Allow the transmission to cool before servicing. Use caution when removing the check, fill or drain plugs from the transmission. 1. Place a drain pan at the rear of the machine. 2. Remove the drain plug from the rear of the transmission (Figure 3). Note: On machines with serial number prior to 259999999, it is recommended that the drain plug be replaced with a magnetic drain plug, Toro Part No. 110–2455. 3.
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Notes: 6
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Notes: 7
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