damaged Timing gear question

gears · Dec 10, 2016

Repairing a Kawasaki engine on a PA540 power unit (JD 525 mower) - ran low on oil with oil sensor/light disconnected. Oil slinger seized to crank gear and ate into lower crankcase housing. I managed to get the thing separated and found that the original gear didn't have an oil groove. I've got another compatible gear from a FA540 and noticed it does have a groove.

Problem is I can't get the damaged gear off the crank! The parts motor's gear just slides off. I've tried pullers, slide hammers, heat. I've heated it so hot (propane torch) that the gear teeth have blued...... since the crank gear drives the hydraulic pump on this stupid power unit, do I need to replace it now? Or should I just put it back together after polishing the scoring on the face of the gear?

I'd like some opinions before I go in there with a cutoff wheel to get the old blued gear out.

used red MN · Dec 10, 2016

Are you sure the crank gear is replaceable on that model? I would check with a dealer. Pictures of
the damage of the gear would also help others give an opinion on its serviceability.

Janicholson · Dec 10, 2016

If you are sure it is removable, use a dremel or die grinder and cut a groove in it almost through and split it with a
wedge. No way will it not come off. Jim

gears · Dec 10, 2016

Here are some pics, the one with the gear slid almost off the crank is my FA540 parts motor (a good running unit) the other is the PA540 power unit which uses the transaxle housing as the bottom engine case.

I figured a dremel cutoff wheel right at the keyway would be the easiest. I would still rather leave things be if there's a concensous that the heated gear will hold up in service.

damaged Timing gear question

gears

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used red MN

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Janicholson

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gears

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