I didn't say they would run better. That bleed hole size is going to change tune of the carb. Any change to it and you will have to make tuning changes.
Most everyone I've talked to settled in the size 40 pilot jet area with no mods to the throttle disk. If you had a bigger bleed hole in the throttle disk i would expect you to need the 42.5 pilot jet.
Did you ever run a size 40 pilot jet over the 37.5 with the original throttle disk?
Just want to set the record straight ... I am NOT modifying any throttle discs in any way, just installing the CORRECT Duraforce one with a 0.10" dia hole in it (98-7047). An incorect disc for R-Tek Snowthrowers was accidentally installed on many Duraforce Lawnmower carbs in 2002 and 2003 which has a 0.055" dia hole in it (Can't confirm Toro p/n since all R-Tek numbers have been converted to B&S numbers).
And as I said, no jetting combination will make a Duraforce Lawnmower run perfect as long as this INCORRECT throttle plate is installed. Well maybe this statement is NOT completely true ... if you were to run your mower in the dead of winter when the air is thinner maybe you could get it to run good with a 0.055" bleed hole !!
With the CORRECT Duraforce throttle plate installed (0.010" hole), my 1999 10323 always ran PERFECT with totally STOCK jetting.
Now to answer your question ... all Duraforces that I've tuned since I've found out about this "Throttle Disc" issue have been running PERFECT on a STOCK main jet and either a "40" or "42.5" Pilot jet. So YES, I've had success with the "40" Pilot Jet.
Some mowers like my 10424 need just a little more to completely eliminate the SURGE (maybe because it is a Push model with no SP Drive load), and the "42.5" Pilot Jet seems to work a bit better.
Doug