Toro aluminum deck broken

[gglabcxyz]

Hi everyone-

I have a 6-year old Toro Super Recycler push mower with an aluminum deck. Up until three weeks ago, it had not given me a problem. My usage is pretty typical: about once a week, yard's about 1/3 acre, season is late April through early November.

Well, while I was mowing my back yard three weeks ago, the left rear wheel appeared to come loose. But when I checked it, it was actually the aluminum deck itself that had broken apart. A small, roughly "D"- shaped piece had completely broken off, which just happened to be the part where the left rear wheel bolted to the deck. The fracture did NOT go through the axle hole, but went "around" it.

Called Toro, took it to the dealer (where the guy said he had never seen anything like this in his 15 years there). They discussed this with a Toro rep, who said there was no sign of a casting defect, so I was out of luck. I asked the dealer what would have caused the deck to break. He said I must have "bumped it against a curb or something". How in the heck could I bump a rear left wheel against a curb with enough force to fracture a cast aluminum deck?

Needless to say I'm pretty disappointed and angry, particularly as the mower is in otherwise great shape. I have taken very good care of it and I am the only person who has ever used it.

Has anyone else out there encountered a problem with an aluminum deck fracturing? Do you think it's worth trying to weld it back together? Also, do you think it would be difficult to find a similar junked mower that I could transplant my engine into?

And for future reference, would you recommend a cast aluminum or a steel deck for me in the future?

Thanks for any thoughts!

 

[MBTRAC]

Cast alloy will fracture if dropped or impacted severely, though it takes a very significant hit, my bet is your Toro has probably had the bad luck to experience a harmonic stress crack which nothing short of a metallurgist/engineer will have the skills to pass judgement on.....

I've repaired a few cast alloy decks using various techniques including pressure "welding" - cast alloy is extremely difficult/expensive to weld effectively - for your situation I'd highly recommend firstly trying a bonding compound which any unskilled person can use as it should prove the most cost effective solution ( J-B Weld 8265-s is a suitable steel/expoxy bond which I'd used successfully on cast alloy, google J-B Weld for more details ), just makes sure to clean the components thoroughly first (use acetone or bake cleaner then allow to dry completely)

Personally, I'd take a cast alloy deck everytime over steel, but then corrision is a big issue where I mow & an alloy deck saves me the bi-annual paint/prep I have to do on my all my steel decks to preserve/"rust proof"

 

[gglabcxyz]

Thanks, MBTRAC. That's why I bought the aluminum deck in the first place, as I thought it would last longer. :frown:

I 'll look into the JB Weld option. Although I'm a little pessimistic that something that simple would withstand the stresses I'd expect near a wheel support, it's a cheap and simple option to try. I did talk to a guy who said he could probably weld the part, but I'd need to get the parts sandblasted first, and I'm having difficulty finding a local shop that can do this.

(Oh, and FYI, I did check into the replacement cost for a new deck. It's almost as much as I paid for the entire mower 6 years ago...)

 

[rustic]

I think you will be pleased with JB Weld option. I used it to bond steering gear box on golf cart for grandkids and it is going strong.

 

[Rivets]

I would get customer service a call and discuss the problem with them. Many times a squeaky wheel would get some grease. No sense go off half cocked, but the worst that could happen is they say no again. I think if you talk reasonably to Toro direct, you just might be able to get some help. I have only seen breaks a couple of times and most were caused by flying rocks. I have had Toro say that they would reduce the cost of the deck for the customer, if he would pay for the labor. Think you dealer should have pushed a little harder if you story is truly accorite. Give it a try, what do you have to lose.

 

[gglabcxyz]

Well, I'm going to give Toro customer service another try as Plan B, but I'm pessimistic they will wind up helping me out since I've already tried to work with them on this. But in the meantime, I'm picking up some JB Weld as Plan A. Looks like it takes a solid day to cure, so with any luck, I'll be back mowing on Sunday.

Which reminds me: Happy Father's Day to all those other dads out there...:smile:

 

[RKennedy]

Well, I'm going to give Toro customer service another try as Plan B, but I'm pessimistic they will wind up helping me out since I've already tried to work with them on this. But in the meantime, I'm picking up some JB Weld as Plan A. Looks like it takes a solid day to cure, so with any luck, I'll be back mowing on Sunday.

Which reminds me: Happy Father's Day to all those other dads out there...:smile:

Just a note: We had the same thing happen with our Toro mower (Model 20056, Super Recycler) that was quite expensive at the time (2005) and recommended by Consumer Reports. Didn't know about trying to epoxy it. Also was at the wheel. Shop said it would be expensive to weld and we ended up just leaving it with them.
We went out and got a cheap Walmart mower to replace it, which we have used in the past for rougher work and they seem to go forever.
The last time we bought an expensive mower was a lawn boy in the mid 1980's that seemed to always have problems starting and running.
We only use the hand mower for trimming and have a riding mower for the bulk of our yard.

 

[chance123]

I would recommend getting it heliarc welded. It's not that expensive and will be strong and permanent.

 

[IndySuburbDude]

Hi everyone-

I have a 6-year old Toro Super Recycler push mower with an aluminum deck. Up until three weeks ago, it had not given me a problem. My usage is pretty typical: about once a week, yard's about 1/3 acre, season is late April through early November.

Well, while I was mowing my back yard three weeks ago, the left rear wheel appeared to come loose. But when I checked it, it was actually the aluminum deck itself that had broken apart. A small, roughly "D"- shaped piece had completely broken off, which just happened to be the part where the left rear wheel bolted to the deck. The fracture did NOT go through the axle hole, but went "around" it.

Called Toro, took it to the dealer (where the guy said he had never seen anything like this in his 15 years there). They discussed this with a Toro rep, who said there was no sign of a casting defect, so I was out of luck. I asked the dealer what would have caused the deck to break. He said I must have "bumped it against a curb or something". How in the heck could I bump a rear left wheel against a curb with enough force to fracture a cast aluminum deck?

Needless to say I'm pretty disappointed and angry, particularly as the mower is in otherwise great shape. I have taken very good care of it and I am the only person who has ever used it.

Has anyone else out there encountered a problem with an aluminum deck fracturing? Do you think it's worth trying to weld it back together? Also, do you think it would be difficult to find a similar junked mower that I could transplant my engine into?

And for future reference, would you recommend a cast aluminum or a steel deck for me in the future?

Thanks for any thoughts!

I know your post is a year old, but just wanted to say that I googled my issue and found it was exactly (I think) the same as yours. I use it normally and my son cuts a couple lawns in the neighborhood with it. Last week, noticed the same problem as you but on front left wheel and starting to happen on the right front wheel too. I don't ever slam the mower into stuff or catch the front wheel and hit it, so I have no idea how this happened. Poor design, is my guess.

 

[iowa toro mower]

Just noticed my left wheel leaning on my Toro Personal Pace Mower. Have had nothing but problems with this 5 year old mower. Replace 4 sets of rear wheels because Toro doesn't disclose the fact that they are not made for hilly lawns. Now my deck is cracked. Never abused this mower at all!!!! Paper thin deck. Hey Toro!!! News flash!! People WILL pay a little more for a quality mower!! Time to buy a Honda mower!!!