Gearbox Reduction Kit

1. Park the machine on a level surface.

2. Ensure that the transmission is in neutral.

3. Lower all attachments (if equipped).

4. Engage the parking brake.

5. Shut off the engine and remove the key.

6. Remove all attachments (if equipped).

7. Raise the front and rear of the machine; refer to the Pre-Maintenance Procedures section in your traction unit Operator’s Manual.

1. Remove the access panel from the right side of the control console (Figure 1).

   

   Figure 1

   1. Panel
   2. Knob

2. Remove and discard the front 2-speed hydraulic hose (Figure 2) from the front hydraulic motor and the tee fitting on the hydraulic manifold.

   Note: The rear 2-speed hydraulic hose should remain installed on the tee fitting.

   

   Figure 2

   1. Tee fitting
   2. Rear 2-speed hydraulic hose
   3. Front 2-speed hydraulic hose
   4. Front hydraulic motor

Note: You can use a drain pan to collect any hydraulic fluid that drains from the machine.

1. Remove the hydraulic hoses (shown in Figure 3) from the front hydraulic motor.

   

   Figure 3

   1. Front motor
   2. Hydraulic hoses
   3. Drain pan

2. Remove the hydraulic hoses (shown in Figure 4) from the rear hydraulic motor.

   

   Figure 4

   1. Rear motor
   2. Hydraulic hoses
   3. Drain pan

3. Remove the hydraulic hoses (shown in Figure 5) from the hydraulic pump.

   

   Figure 5

   1. Hydraulic pump
   2. Hydraulic hoses

1. Remove the bolts that secure the hydraulic motor to the front axle (Figure 6). Retain the bolts.

   

   Figure 6

   1. Bolts (retain)
   2. Bolts and thin metal sheet covers (discard)

2. Remove the bolts and the thin sheet metal covers (Figure 6). Discard the bolts and metal covers.

3. Drain the parking-brake fluid at the rear axle (Figure 7).

   Note: This reduces the mess when the hydraulic motor and parking brake are separated from the axle.

   

   Figure 7

   1. Drain port
   2. Drain plug
   3. Drain pan
   4. Parking brake

4. Remove the 2 bolts that secure the hydraulic motor to the parking brake and the rear axle (Figure 8).

   • Retain the bolts (1/2 x 5 inches) for installing the gearbox adapter to the parking brake.

   • There is a gasket that seals the surface between the parking brake and the hydraulic motor (shown in Figure 11). Install a new gasket when you install the gearbox adapter. The gasket is not needed on the front axle.

   Note: The parking brake should remain mounted to the axle.

   

   Figure 8

   1. Bolts

Parts needed for this procedure:

Connect the appropriate hydraulic hoses to the hydraulic-pump ports as shown in Figure 9.

Note: The curved end of each hose must be installed to the pump. The straight end of each hose will be installed to the motors later.

Figure 9

1. 122 cm (48 inches) hose to pump port A
2. 109 cm (43 inches) hose to pump port D
3. 122 cm (48 inches) hose to pump port B
4. 109 cm (43 inches) hose to pump port C

Parts needed for this procedure:

1. Remove the gearbox adapters from the gearboxes (Figure 10).

   

   Figure 10

   1. Gearbox
   2. Gearbox adapter
   3. Bolt

2. Install a gearbox adapter and a gasket on the rear axle using the existing bolts (1/2 x 5 inches). Position the adapter with “” towards the top of the machine (Figure 11).

   Torque the bolts to 98 to 106 N∙m (72 to 78 ft-lb).

   

   Figure 11

   1. Gasket
   2. Gearbox adapter
   3. Bolts (1/2 x 5 inches)

3. Install a gearbox adapter on the front axle using the existing bolts. Position the adapter with “” towards the top of the machine (Figure 12).

   Torque the bolts to 98 to 106 N∙m (72 to 78 ft-lb).

   

   Figure 12

   1. Bolts (3/8 x 1-1/4 inches)
   2. Gearbox adapter

4. Apply anti-seize compound to all surfaces of the gearbox output-shaft splines prior to installation (Figure 13).

   

   Figure 13

   1. Gearbox output-shaft splines

5. Lightly oil the O-ring (3 inches) and install the O-ring and a gearbox on the rear axle (Figure 14).

   Note: The gearbox will pilot onto the adapter; there are 4 mounting holes that will line up with the adapter.The gearbox should be positioned horizontally to the ground.

   

   Figure 14

   1. Bolts (3/8 x 1-1/4 inches)
   2. O-ring (3 inches)
   3. Gearbox

6. Use 4 hex-head bolts (3/8 x 1-1/4 inches) to secure the gearbox to the adapter (Figure 15); torque the bolts to 39 to 45 N∙m (29 to 33 ft-lb).

7. Apply anti-seize compound to all surfaces of the output-shaft splines for the second gearbox (Figure 13).

8. Install the second gearbox on the front axle (Figure 15).

   Note: The hydraulic motor mount will be angled with respect to the ground.

   

   Figure 15

   1. Bolts (3/8 x 1-1/4 inches)
   2. Gearbox

9. Use 4 hex-head bolts (3/8 x 1-1/4 inches) to secure the gearbox to the adapter (Figure 15); torque the bolts to 39 to 45 N∙m (29 to 33 ft-lb).

Parts needed for this procedure:

1. Prior to installing the hydraulic motors, lightly oil an O-ring and install onto the hydraulic-motor pilot. Ensure that the O-ring is not twisted.

2. Apply anti-seize compound to all surfaces of the motor output-shaft splines.

3. For each hydraulic motor, use 2 hex-head bolts (1/2 x 1-1/4 inches) to secure the motor to the gearbox (Figure 16).

   Torque the bolts to 98 to 106 N∙m (72 to 78 ft-lb).

   

   Figure 16

   Rear hydraulic motor shown.

   1. Hex-head bolts (1/2 x 1-1/4 inches)
   2. Hydraulic motor
   3. O-ring
   4. Gearbox

Parts needed for this procedure:

Installing the Hydraulic-Pump Hoses to the Motors

The following table shows the appropriate hose connections. Figure 17 identifies the hose connections at the hydraulic pump.

Motor Port and Pump Port Connections

Pump Port	Motor	Motor Port	Figure 9 Callout
A	Front	M2	1
B	Front	M1	2
D	Rear	M1	3
C	Rear	M2	4

Figure 17

1. Pump port A to front motor hose (M2)
2. Pump port D to rear motor hose (M1)
3. Pump port B to front motor hose (M1)
4. Pump port C to rear motor hose (M2)

1. Connect the previously installed hydraulic-pump hoses to the hydraulic motors as follows:

   1. Connect the hydraulic hoses (109 cm or 43 inches) to the rear hydraulic motors (Figure 18).

      

      Figure 18

      Rear motor shown

      1. Port M1 (from pump port D)
      2. Port M2 (from pump port C)

   2. Connect the hydraulic hoses (122 cm or 48 inches) to the front hydraulic motors (Figure 19).

      

      Figure 19

      Front motor shown

      1. Port M1 (from pump port B)
      2. Hose to Port M2 (from pump port A)

2. Use the cable ties to secure the hose protectors to the hydraulic hoses (109 cm or 43 inches) as shown in Figure 20.

   

   Figure 20

   1. Hose protectors

3. Torque the hose fittings to 149 to 164 N∙m (110 to 121 ft-lb).

Parts needed for this procedure:

1. Remove the plug on the upper area of both gearboxes (Figure 23) and discard it.

   

   Figure 23

   1. Plug

2. Install a 90° hydraulic fitting oriented 55° from vertical on the gearbox (as shown in Figure 24 and Figure 25); torque the fitting to 49 to 54 N∙m (36 to 40 ft-lb).

   Note: The fitting must be tilted so the bellows do not contact other parts.

   

   Figure 24

   Front gearbox shown

   

   Figure 25

   Rear gearbox shown

3. Apply pipe sealant compound or thread-sealing tape to the threads on the hose barb.

   

   Figure 26

   1. Bellows
   2. Spring clamp
   3. Hose barb
   4. 90° hydraulic fitting
   5. Gearbox opening

4. Install the hose barb into the hydraulic fitting (Figure 26).

5. Install the spring clamp to the bellows and secure the bellows to the hose barb with the spring clamp (Figure 26).

6. Remove the plug from the front of the front gearbox and replace it with the included sight plug.

Fluid specification: Toro Premium Tractor Fluid

Add fluid to the front and rear gearboxes; refer to Changing the Front Traction-Gearbox Oil and Changing the Rear Traction-Gearbox Oil.

Fluid specification: Toro Premium Tractor Fluid

1. Remove the fill plug at the top of the brake housing (Figure 27).

   

   Figure 27

   1. Fill plug
   2. Fill port
   3. Drain pan

2. Fill the brake housing with 160 ml (5.4 fl oz) of the specified oil through the fill port.

3. Apply PTFE thread sealant to the fill plug (Figure 27) and tighten it 3 turns past finger-tight.

Use Toro DIAG to update the traction-unit software to Rev H; refer to the Toro DIAG Software User’s Guide for instructions to update the software.

Perform the following steps to complete the installation:

• Check the hydraulic-fluid level and add more fluid as needed; refer to the hydraulic system maintenance section in the traction unit Operator’s Manual.

• Ensure that the machine moves forward when the shift lever is in the FORWARD position; ensure that it moves backward when the lever is in the REVERSE position.

• Ensure that the machine does not move faster than 23 km/h (14 mph) during operation. The InfoCenter displays the current machine speed.

• Ensure that there are no unusual noises or leaks.

• Ensure that the machine operates smoothly when changing speed or direction.

Oil specification: Toro Premium Tractor Fluid

Oil specification: Toro Premium Tractor Fluid