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Hi all,
Have a different issue from my mikuni carb finally .....cannot get the pinion gear off the end of the drive axle on the above mower......copious amounts of Deep Creep penetrant over 3 days, and also heat from a torch to almost red hot.....still won"t come off!!! And in trying to pry it off I've destroyed the plastic washer that sits behind it, so in order to repair both, the pinion gear has to come off!!!
Any other suggestions greatly appreciated.

Might try a 3 jaw puller if applicable . May locate one at a tool rental if owning isn't wanted .

It is going to be rusted on.

More likely need a bearing separator puller with disposable pusher block. With some good penetrating oil or maybe even some heat.

Star Tech.....see my original post. Both heat and penetrating oil have been used extensively with no luck. Searching for a bearing separator now....will a two inch one work behind such a small pinion gear.....about 1 1/2"??

here's the problem....

trooper1954 said:

Star Tech.....see my original post. Both heat and penetrating oil have been used extensively with no luck. Searching for a bearing separator now....will a two inch one work behind such a small pinion gear.....about 1 1/2"??

Click to expand...

Here is something I suspect going here too. The groove for the retaining ring has flared. Push the gear back on and file the ridge off the shaft at the retaining area. This flaring is like knurling by increasing the shaft diameter thus binding even tighter as you attempt to pull past it. Due to close tolerances already present this is like beating to shaft end, flaring the shaft. Imagine that you trying to pull something off a taper shaft the wrong direction, just not possible. It doesn't take a whole lot to cause problems.

Hi guys.....quick update....
Bearing separator arrived yesterday, and pinion gear is on its way out!! Only problem was the drive screw in the center that actually does the pulling even tho pointy, was a little bit too wide for the rectangular hole in the end of the gear. I think I'll just file it down for now, or look for a bolt with the same thread and file it instead.
One other question....in trying to remove the gear before I got the separator, I destroyed what appears to be either a fibre or plastic washer on the drive shaft on the inside. I've looked at numerous parts diagrams of this transmission system but none show this washer....any ideas what its called and how I would order a new one?
Have included a picture of the other side.
Mower is a Toro 20055 serial # 250008366
Thanks

Maybe this manual will help you out. https://www.toro.com/getpub/22446

Thx Rivets, but you already sent me this from another forum....have been through it twice, and cannot find that washer anywhere...appreciate the thought tho.