Rob, the right side has the same thing. If you'll look closely, at the end of the axle, wheel off, you will find a small hole. If you'll get a point tip for your grease gun or buy one if you don't have a gun, remove both drive wheels once per year and pump grease in that hole until grease comes out of the gear. This flush's out dirt and grit and leave a fresh supply of grease. Owners manual will tell you to grease these buggers once per year and will stop the problem from coming back. Yours is two years old so you should be fine. Early production did not have a hole in the end of the axle and one had to do the full dis-assembly you did.

Ok folks here it goes. Although there are many things that can cause a Toro personal pace to make all kinds of noises I would like to let you know how to fix at least one issue. After excluding wheel grinding noises and adjustment issues here is an easy fix to the transmission grinding noise. This noise can occur even with good gears and no gear slippage. The problem is that Toro has not chosen to fix a tolerance problem in the transmission casting or case itself. Now make a mental picture of what I am about to say or be staring down inside the transmission housing and gears by removing the axle and transmission unit. The bearing sits in the bottom of the transmission housing then the pinion gear stem fits down through it to the pulley system. The pinion gear then engages the bevel gear on the axel. Now here is the problem; the bearing when sitting in the bottom of the case allows just enough disengagement to create a grinding or howling noise. You may think my solution is quirky but it darn sure has worked. I took a wrench socket and knocked the bearing away from the floor of the transmission case a bit. I then took a piece of baling wire shaped like a washer and worked it between this created space between the floor of the case and the lower or bottom side of the bearing. This moves the pinion gear and the beveled gear to exactly to the correct tolerances. Hence, no more grinding noise. I have a 2005 Personal Pace mower that is actually quieter than when it was new.

Thanks for your responce. There is play in the input shaft, which is the pinion gear shaft that goes through a pressed in bearing. Don't know if there should be some or any play at that point but the shaft probably goes 10 degrees or so off of center, had that play when taken apart and service manuel does not specifi if any rocking motion in pinion shaft at that point. Bearing did look OK but don't know about rocking motion.

I purchased the Toro 20066 on 8/9/08, after comparing the Toro to the Honda and Snapper. I am very pleased about everything this mower provides with one exception...the bagging. The clippings blow out the top right-hand side of the bag and there is not enough force to push the clipping to the back of the bag. So when bagging I am left with a trail of clippings and when I empty the bag I am left having to clean up the clipping that essentially plug up at the discharge chute. I went to the FAQ section on the Toro web site and they tell you "in the upper corners of the bag, there is a small plastic flap that will close off any gaps. When installed correctly, air pressure pushes the flap out to the frame and closes off the opening." This does not work. It is a poor design considering the mower deck is contoured and the bag fitting is straight. I am currently waiting for a response from Toro. I have used this mower three times and I am already pulling my hair out. This is design flaw. I have spoken to an authorized dealer/repair store and they have had numerous complaints about this issue. The service person even suggested changing from the issued mulching blade to a standard cutting blade. Several of his customers have recently done this but he has not heard back to see if this has solved the problem of at least getting the clipping to the back of the bag. If you are serious about bagging I would not recommend this mower.