Usage:
Start By:
a. remove rear wheel assemblies
b. remove axle propel motor
NOTE: The planetary carrier assemblies do not need to be removed.
1. Using a lift truck, install block (1) between fork and differential.
2. Install blocking (3) at both sides. Remove eight nuts (2) and lower the axle until there is clearance to remove the axle from under the machine. The weight of the axle is 580 kg (1300 lb).
NOTE: To install rear axle, reverse the removal steps.
End By:
a. install rear wheel assemblies
b. install axle propel motor
Disassemble Torque Hub (Soma Axle And Differential)
NOTE: Clean the outside of the torque hub thoroughly before starting disassembly. Perform disassembly and assembly in a clean work area to prevent contaminants from entering the torque hub.
1. Make matching scribe marks on the cover, ring gear, and hub. This will help ensure that these parts are reassembled in their original positions.
2. Remove one or more plugs to drain lubricant from the torque hub. Replace the plug after lubricant has drained.
NOTE: The cover is secured to the torque hub with eight standard bolts (24) and four shoulder bolts (25). These bolts are positioned in the cover as shown above.
3. Remove eight standard bolts (24) from cover (16).
4. Remove four shoulder bolts (25) from cover (16).
5. Remove cover (16), one O-ring (22), and two thrust washers (23) and (14) off the torque hub. Discard O-ring (22). This must be replaced with a new part during assembly.
6. Remove input gear (15).
7. Remove ring gear (9) and remaining O-ring (26). Discard O-ring (23). This must be replaced with a new part during assembly.
8. Remove carrier (5).
9. Place a bearing cone pressing tool on top of retaining ring (21) inside the hub.
10. Press the tool with a hydraulic ram or by striking with a soft face hammer. Pressure should be applied until hub (3) rotates with difficulty. This step is necessary to remove the preload against retaining ring (21).
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Wear safety glasses to prevent injury from possible flying parts during the following step. |
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11. Use retaining ring pliers to remove retaining ring (21). Remove spacer (4). Discard retaining ring (21). This must be replaced with a new part during assembly.
12. Press spindle or output shaft (17) out of hub (3).
13. Pull outer bearing cone (19) out of hub (3).
14. Pull inner bearing cone (1) and seal (18) off spindle or output shaft (17). Discard seal (18). This must be replaced with a new part during assembly.
15. Press two bearing cups (2) and (20) out of hub (3).
16. Drive roll pin (6) out of one of the planet shafts (12).
17. Remove planet shaft (12) from carrier (5).
18. Remove planet gear (13) and two thrust washers (7) from the carrier.
19. Remove two rows of needle rollers (8) and one spacer (10) from the bore of the planet gear.
20. Repeat Steps 16 through 19 for the remaining two planet gears.
21. Wash all parts in clean solvent. Dry parts thoroughly and inspect for damage or excessive wear. Replace parts as necessary before assembly.
Assemble Torque Hub
1. Apply a coat of grease inside the bore of one planet gear (13). This will hold needle rollers (8) in place during assembly.
2. Install the first row of 16 needle rollers (8) into the bore of the planet gear.
3. Set spacer (10) into the bore of planet gear (13) on top of the needle rollers.
4. Install a second row of 16 needle rollers (8) into the bore of the planet gear.
5. Apply grease to the tang side of the two thrust washers. Place the thrust washers against bosses in carrier (5). Washer tangs must fit into slots in carrier's outside diameter.
6. When the thrust washers are in place, slide planet gear (13) between them. Line up the planet gear bore with the hole in the carrier.
7. Install one planet shaft (12) through the carrier and planet gear. Line up the roll pin hole in the planet shaft with the carrier roll pin hole.
8. Drive roll pin (6) into the carrier hole, locking the planet shaft in place. Make sure the roll pin is driven at least flush with the carrier.
9. Repeat Steps 1 through 8 for the remaining two planet gears.
10. If the torque hub uses a spindle (17), as shown above, prepare for assembly as follows:
a. Apply a light film of oil to a new seal (18).
b. Press the seal onto the spindle shoulder so that the closed end of the seal faces the spindle drive plate. Make sure the seal is installed square with the spindle.
c. Press inner bearing cone (1) onto spindle (17).
11. If the torque hub uses an output shaft (17), as shown above, press inner bearing cone (1) onto the output shaft. Seal (18) will be installed in a later step.
12. Press inner bearing cup (2) and outer bearing cup (20) in place inside hub (3).
13. Carefully raise hub (3) and set in place on spindle or output shaft (17). Use care to prevent damaging the seal, if installed.
14. Press outer bearing cone (19) on the spindle or output shaft inside hub (3). Rotate the hub while pressing the bearing. Stop pressing when the hub starts to resist rolling.
15. Install spacer (4) so that it rests on top of the outer bearing cone.
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Wear safety glasses to prevent injury from possible flying parts during the following step. |
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16. Use retaining ring pliers to install a new retaining ring (21) into the groove on the spindle or output shaft. Use a soft punch against the retaining ring to be sure it is seated.
17. Apply a light coat of grease to one new O-ring (26). Install the O-ring into the counter-bore of the hub.
18. Install carrier (5) into the torque hub. Make sure the internal spline of the carrier engages the spline of the spindle or output shaft inside the hub.
19. Slide ring gear (9), with the shoulder side toward the hub, into mesh with the planet gears. Be sure to align the scribe marks made during disassembly.
20. Slide input gear (15) into mesh with the planet gears inside the carrier until it rests against the shoulder.
21. Place small thrust washer (23) over the input gear.
22. Apply grease to one side of large thrust washer (14). Place the thrust washer on the counter-bore of the carrier with the greased side facing the torque hub cover.
23. Apply a light coat of grease to the second new O-ring (22). Install the O-ring into the counter-bore of cover (16).
24. Install cover (16) to the torque hub. Be sure to align the scribe marks made during disassembly.
25. Install four shoulder bolts (25) into the torque hub cover as shown. Tighten the bolts to 31 to 36 N·m (23 to 27 lb ft).
26. Install eight standard bolts (24) into the torque hub cover as shown. Tighten the bolts to 31 to 36 N·m (23 to 27 lb ft).
27. If the torque hub uses an output shaft (17), as shown above, install a new seal (18) as follows:
a. Apply a light film of oil to a new seal (18).
b. Position the seal so the closed end faces out. Tap the seal into place so it is flush with the hub.
28. Refill the torque hub with lubricant. See the Operation and Maintenance Manual for lubricant information.
Disassemble Rear Axle And Differential (Soma)
NOTE: Determine the style of differential by consulting the Parts Book, Form No. KELP2520.
Start By:
a. remove rear axle
1. Remove the drain plug at the bottom of the axle housing to drain lubricant. Replace the plug after lubricant has drained.
2. Remove the fasteners securing the differential and carrier assembly to the axle housing. Remove the differential and carrier assembly and secure to a work stand.
3. Remove the nuts, bolts, and washers securing the adapter housing to the axle. Remove the adapter housing.
4. Remove the snap ring, gear coupler, and adapter gear from inside the adapter housing.
5. Attach a holding tool to the pinion gear to prevent it from turning. Remove the nut and washer securing the pinion gear. Remove the pinion gear.
6. Turn the differential and carrier as shown. Remove the bolts and washers securing the lock plates at each side of the differential. Remove the lock plates.
7. Remove bolts and washers securing the bearing caps to the case.
8. Remove the bearing caps, adjusting nuts, and bearing cups from both sides of the differential.
9. Use a hoist or other suitable lifting device to lift the differential away from the carrier. Set the differential aside.
10. Remove bolts and washers securing the seal retainer to the front of the case.
11. Thread two pusher bolts into the seal retainer. Turn the bolts in equally to remove the seal retainer.
12. Thread two pusher bolts into the bearing cage. Turn the bolts in equally to remove the bearing cage assembly.
13. Support the bearing cage and bevel pinion as shown. Press the bevel pinion out of the bearing cage. Collect the shims and spacer.
14. Press the inner bearing cone off the bevel pinion, if necessary, for replacement.
15. Bend crimping on the end of the bevel pinion to allow removal of the rear bearing.
16. Remove the rear bearing using a puller as shown.
17. If a clutch collar is present on the differential, remove the locking screws and draw out the clutch collar.
18. Set a steel plug on the end of the differential. Use a puller to remove the bearing cone if necessary for replacement.
19. Repeat Steps 17 and 18 for the other side of the differential.
20. Remove nuts and bolts securing the ring gear to the differential. Remove the ring gear.
21. Remove bolts holding the differential together.
22. Disassemble the components of the differential.
23. Wash all parts in clean solvent. Dry parts thoroughly and inspect for damage or excessive wear. Replace parts as necessary before assembly.
Assemble Rear Axle And Differential (Soma)
NOTE: To determine axle type, refer to Parts Book, Form No. KELP2520.
1. Install components into one case half of the differential without oil. Exert pressure on center of spider. Use a dial indicator to measure the backlash between the side gear teeth.
2. Backlash should be .20 to .30 mm (.010 to .015 in.). If backlash is excessive, change the thrust washer inside the differential.
3. Repeat Steps 1 and 2 with differential components installed in the remaining case half.
4. Oil the components of the differential, and assemble.
5. Install bolts holding the differential together.
6. Heat both bearing cones in a furnace or oil bath to about 80°C (175°F). Install the heated bearings onto the ends of the differential.
7. Install the ring gear onto the differential and secure with nuts and bolts.
8. Find the thickness of the shims to be installed in the bearing cage as follows:
a. Install the rear bearing cone (without oil) into the bearing cage.
b. Hold a straight edge on the bearing cone, as shown, and press down with a force of 50 N·m (39 lb ft). Use shims to measure Dimension "A", between a 50.2 mm gauge and the straight edge.
c. Record Dimension "A". This will be used again in a later calculation.
d. Install the spacer, shims, and front bearing cone into the bearing cage.
e. Press front bearing cone as shown. Use levers to place upward force on the bearing cage. Measure the clearance with a dial indicator.
f. Adjust the shim thickness so the bearing cage assembly is without clearance.
9. Remove both bearing cones, shims, and spacers from the bearing cage.
10. Heat the rear bearing in a furnace or oil bath to about 80°C (175°F). Install the heated bearing onto the bevel pinion.
11. Use a hammer and chisel to bend metal outward, as shown, to secure the rear bearing.
12. Heat the rear bearing cone to about 80°C (175°F). Install the bearing cone on the bevel pinion.
13. Install the bearing cage, shims, spacer, and front bearing cone onto the bevel pinion.
14. Press the front bearing cone into place using a suitable sleeve.
15. Install the bevel pinion assembly into the differential case. Find the shim thickness to be added to the assembly as follows:
a. Subtract Dimension "A" (recorded in Step 8) from the size marked on the case.
b. Compare the number found in Step (a) with the theoretical size for the model axle used. The difference of these two figures gives the correction needed for a gear set of a theoretical size.
c. After adjusting, correct the size marked on the gear set.
Example:
Size marked on the case 230.65
Dimension "A" 50.3
Gear set correction needed 0.40
Theoretical size (1250) 180.975
Calculations:
230.65 - 50.3 = 180.35
180.975 - 180.35 = 0.625
0.625 + 0.40 = 1.025
16. Coat shims with Hyperix and set in place. Be sure to align the lubrication holes.
17. Secure the bevel pinion assembly with four bolts.
18. Set the seal retainer in place over the bevel pinion.
19. Secure the seal retainer with bolts and washers.
20. Install the pinion gear, washer, and nut onto the bevel pinion.
21. Attach a holding tool to the pinion gear to prevent it from turning. Tighten the nut.
22. Rotate the bevel pinion a few times to make sure it turns smoothly. Stake the nut to prevent it from coming loose.
23. Using a hoist or other suitable lifting device, raise the differential assembly and set in place in the carrier.
24. Install bearing cups, adjusting nuts and bearing caps onto each side of the differential. Do not tighten the bolts securing the bearing caps.
25. Adjust the differential as follows:
a. Fully tighten both adjusting nuts (A) and (B).
b. Loosen nut (A) by two notches and tighten nut (B) by two notches.
c. Check if the assembly turns. Use a dial indicator to measure tooth backlash.
d. Backlash must be .20 to .30 mm (.08 to .12 in.). End play must be zero. Adjust if needed.
26. Check the contact of ring gear teeth with bevel pinion teeth as follows:
a. Paint about 10 ring gear teeth with a commercial marking compound.
b. Rotate the bevel pinion forward and backward a few times so the painted gear teeth go past the pinion several times.
c. A good contact pattern should appear as above.
NOTE: Make sure gear backlash is maintained at .20 to .30 mm (.08 to .12 in.). This is important to maintain the life of the gear set.
d. If the contact pattern appears as above, the ring gear must be moved away from the bevel pinion, as shown. The position of the bevel pinion must also be adjusted.
e. If the contact pattern appears as above, the bevel pinion must be away from the ring gear. Move the ring gear closer to the bevel pinion as shown.
f. If the contact pattern appears as above, the ring gear must be moved toward the bevel pinion as shown. The position of the bevel pinion must also be adjusted.
g. If the contact pattern appears as above, the ring gear must be moved away from the bevel pinion to maintain correct backlash. The position of the bevel pinion must also be adjusted.
27. Tighten the bolts securing the bearing caps. Install the lock plates and secure with bolts and washers. Lock the bolts and nuts.
28. Install the thrust screw, if used. Tighten the thrust screw so it contacts ring gear, then loosen a half turn. Tighten and lock the nut.
29. Install gear coupler, adapter gear, and snap ring into the adapter housing.
30. Install the adapter housing to the axle. Secure with nuts, bolts, and washers.
31. Install the differential and carrier assembly into the axle housing. Secure with fasteners.
NOTE: Refill the axle with lubricant. See the Operation and Maintenance Manual for lubricant information.
End By:
a. install rear axle
Disassemble Planetary Wheel Ends (Soma)
1. Position the wheel end so the drain plug is at the bottom position. Remove the plug to drain lubricant. Replace the plug after lubricant has drained.
2. Remove bolts and washers securing the cover to the hub.
3. Use screwdrivers to pry the cover away from the hub.
4. Remove the thrust button from the cover.
5. Remove the paper seal from the cover. Clean the cover and the mating surface of the planetary carrier with a scraper and a fine-grain abrasive paper. This is necessary to assure that these parts seal properly after assembly.
6. Remove the shaft end positioner from the bore of the axle shaft.
7. Remove the snap ring from the end of the axle shaft.
8. Remove locater bolts securing planetary carrier assembly to the hub.
9. Remove the planetary carrier assembly.
10. Remove the O-ring from the groove inside the hub. Discard the O-ring. This must be replaced with a new part during assembly.
NOTE: Planetary assembly should not be disassembled further. This unit is serviced as an assembly.
11. Remove the sun gear from the end of the axle shaft.
12. Remove one spindle nut, one locking washer, and a second spindle nut from the axle housing inside the wheel end.
13. Remove the cone by prying with a screwdriver or by knocking the ring gear with a leather hammer.
14. Remove the ring gear assembly.
15. Drive the outer bearing cone off ring gear, if necessary, using a drift and hammer. Place the drift through the drilled holes in the ring gear for removing the bearing cone.
NOTE: Ring gear assembly should not be disassembled further. This unit is serviced as an assembly.
16. Pull the hub off the axle housing.
17. Use a screwdriver or lever tool to remove two seals (4) and (5) from inside the hub. Discard both seals. These must be replaced with new parts during assembly.
18. Pull inner bearing cup (3) and outer bearing cup (2) out of the hub if bearings are being replaced.
19. Pull the axle shaft out of the housing.
20. Pull the inner bearing cone off axle housing, if necessary to replace.
21. Wash all parts in clean solvent. Dry parts thoroughly and inspect for damage or excessive wear. Replace parts as necessary before assembly.
Assemble Planetary Wheel Ends (Soma)
1. Heat the inner bearing cone in a furnace or oil bath to about 80°C (175°F). Install the heated bearing onto the axle housing.
2. Press the inner bearing cup (3) and outer bearing cup (2) into place inside the hub.
3. Install two new seals (4) and (5) into hub (1).
4. Install the hub onto the axle housing, taking care not to damage the seals.
5. Heat the outer bearing cone in a furnace or oil bath to about 80°C (175°F). Install the heated bearing onto the ring gear assembly.
6. Install the ring gear assembly inside the hub.
7. Insert the cone into place inside the ring gear. Secure the ring gear by installing a spindle nut, a locking washer, and a second spindle nut.
8. Tighten the spindle nut to 16 N·m (22 lb ft) while rotating the hub and striking with a mallet.
9. Install a new O-ring in the groove inside the hub.
10. Install the planetary carrier to the hub. Secure with locater bolts.
11. Install the axle shaft into the housing.
12. Install the sun gear onto the end of the axle shaft. Secure with snap ring.
13. Install the shaft end positioner into the bore of the axle shaft. Use a sliding gauge to measure the backlash of the axle shaft.
14. Backlash must be 1.5 to 3.0 mm (.06 to .12 in.). If backlash is not correct, shims may be used as needed.
15. Install the thrust button into the cover.
16. Spread a small amount of 5H2471 Cement on the cover. Install a new paper seal as shown.
17. Install the cover onto the hub. Secure with bolts and washers.
18. Tighten the bolts in a pattern, as shown, to the following torques:
- a. 19 mm bolts: 140 N·m (102 lb ft)
- b. 17 mm bolts: 68 N·m (50 lb ft)
- c. 10 mm bolts: 30 N·m (20 lb ft)
- b. 17 mm bolts: 68 N·m (50 lb ft)
NOTE: Refill the wheel ends with lubricant. See the Operation and Maintenance Manual for lubricant information.
Disassemble Axle And Differential (Clark)
NOTE: To determine axle type, see Parts Book, Form No. KELP2520.
Start By:
a. remove axle
NOTE: Drain axle wheel ends and center section before disassembly.
| NOTICE |
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Cleanliness is of extreme importance in the repair and overhaul of this unit. Before attempting any repairs of this unit, clean the exterior to prevent the possibility of dirt or foreign matter entering the mechanism. |
1. Remove the planetary cover capscrews and the cover.
2. Pull the axle shaft and sun gear out of the wheel end.
3. Remove the sun gear retaining ring and remove the sun gear and thrust washer.
4. Remove the planetary carrier capscrews.
5. Tap the planetary carrier from the wheel hub far enough to attach a hoist.
6. Remove the planetary carrier assembly.
7. Press the pinion shaft from the planetary carrier assembly. Take care not to lose the pinion shaft lock ball.
8. Remove the pinion gear, rollers, spacers and thrust washers from the carrier housing.
9. Remove the outer jam nut and nut lock. Loosen the wheel bearing adjusting nut but do not remove the nut at this time.
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When the hub and drum assembly is removed, the axle housing will be heavy on the other end. This may cause the axle housing to flip. Be sure to secure the axle housing to prevent any movement after removal. |
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10. Attach a hoist to the wheel hub.
11. Remove the wheel bearing adjusting nut and washer. Remove the internal gear and hub assembly.
12. Remove the wheel hub assembly.
13. Remove the spindle bolts, nuts and washers. Remove the spindle.
NOTE: Some units may have a wheel hub oil seal protector and some units will not.
14. Repeat Steps 1 through 13 for the opposite wheel end assembly.
15. Turn the axle housing so the differential input flange is facing up.
16. Remove the drop gear bolts and nuts.
17. Remove the taper dowels by tapping a small screwdriver in the taper dowel slots.
18. Remove the drop gear cover.
19. Use a small brass bar to prevent the drop gears from turning and remove the pinion shaft nut.
20. The gear ratio will determine if the large pinion drop gear are under the small drop gear bearing. If the gear teeth are under the bearing, remove the small drop gear outer bearing.
21. Remove the large drop gear.
22. Remove the small drop gear and the inner bearing.
23. Remove the drop gear housing bolts and washers.
24. Remove the drop gear housing. Turn the differential assembly over so the ring gear faces up. If the unit has a ring gear thrust screw, remove the jam nut and thrust screw.
25. Check and record the ring gear backlash with a dial indicator. This information is necessary for reassembly unless a new gear set is installed.
26. Use a center punch to mark the bearing caps and the carrier assembly. This is to insure a correct match at reassembly.
27. Remove the adjusting nut lock, screw and washer.
28. Remove the bolts securing the bearing caps to the carrier assembly. Remove the caps and adjusting nuts.
29. Install a metal bar through the differential to help in hoisting. Raise the ends one at a time to remove the bearing cups.
30. Raise the differential on an angle to permit the ring gear to clear the pinion shaft inner bearing boss in the carrier assembly. Remove the differential.
31. Use a center punch to mark the case halves for reassembly purposes.
32. Using a two arm puller, replace the differential bearings as necessary.
33. Remove the ring gear.
34. Mark the mating halves of the differential case with a center punch for reassembly purposes.
35. Insert a retaining bolt and washer assembly as shown. Notice the washers must be small enough to pass through the case ends (dimension A), yet large enough to restrain the two side gears against the compressed springs inside the differential (dimension B).
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Failure to use a retaining bolt in the following step can cause injury due to the sudden release of the compressed springs inside the No-Spin differential. |
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36. Remove eight bolts and washers securing the cover to the case. Remove the No-Spin differential from inside the case.
37. Carefully remove the retaining bolt and washers while firmly holding the differential to absorb the spring force.
NOTE: Further disassembly of the No-Spin assembly is for inspection purposes only. The No-Spin assembly should be serviced as a unit.
38. Remove the side gears, spring retainers, springs, driven clutch assemblies and the spider assembly.
NOTE: The driven clutch assemblies consist of driven clutch (8) and holdout ring (9). These two parts should not be separated. If one part is damaged, the entire driven clutch assembly must be replaced.
NOTE: The spider assembly consists of spider (10) and center cam (11). These two parts should not be separated. If one part is damaged, the entire spider assembly must be replaced.
39. Inspect the splines on driven clutches (8). Remove any burrs or small chips.
40. Inspect the teeth on driven clutches (8).
41. Check holdout rings (9) for fractures and chipping or excessive wear of the teeth.
42. Inspect the teeth on spider (10) and center cam (11).
43. Make sure center cam (11) moves freely inside the spider assembly.
44. Inspect the splines on the side gears. Remove any burrs or small chips. Make sure the splines do not bind on the mating axle shaft.
45. Check the springs for proper load. The force of the compressed spring should be 29 ± 3 kg (65 ± 7 lb).
46. Examine the case and cover for damage.
| NOTICE |
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If major components show excessive wear, the complete No-Spin differential should be replaced. If a part is replaced, mating parts should also be replaced. The use of worn or damaged components may lead to a recurrence of the original problem. |
47. Turn the differential over. Using the pry spots provided, remove the bearing cone, cage, spacer and shims. Retain and use the same shims on reassembly.
48. Press the pinion assembly from the carrier.
49. Press the center bearing cone from the pinion assembly.
50. Press the inner bearing from the pinion assembly.
NOTE: Clean and inspect all parts for wear and damage.
Assemble Axle And Differential (Clark)
NOTE: To determine axle type, see Parts book, Form No. KELP2520
NOTE: Lubricate all bearings, gears and thrust washers on assembly.
1. Check the ring gear mounting surface of the flanged half of the differential case for burrs. This surface must be smooth and clean.
2. Set the differential case on a bench with the bearing end down and the inner case face facing upward.
3. Assemble one spring retainer over the side gear splines with the retaining lip pointed up. It should seat against the side gear shoulder.
4. Install one spring over the side gear spline and against the retainer lip, with the small diameter of the spring against the retainer.
5. Install one driven clutch assembly over the spring with the teeth up.
6. Compress the driven clutch assembly over the side gear splines a few times. Make sure the spring does not bind and the coils do not overlap. See that there is good contact between the end coil and the spring retainer when the driven clutch and side gear splines are fully meshed.
7. Position the spider assembly over the driven clutch assembly. Make sure long tooth (12) of the spider is positioned over slot (13) in the holdout ring.
8. Position the other driven clutch assembly over the spider assembly. Make sure slot (13) in the holdout ring is positioned over long tooth (12) in the spider.
9. Assemble the remaining spring retainer over the splines of the remaining side gear. Make sure the retaining lip is pointed up and the spring retainer seats against the side gear shoulder.
10. Install the remaining spring over the side gear spline and against the retainer lip. Make sure the small diameter of the spring is against the retainer.
11. Install the side gear, spring retainer and spring assembly over the driven clutch, with the side gear facing up.
12. Compress the side gear over the driven clutch a few times. Make sure the spring does not bind and the coils do not overlap. See that there is good contact between the end coil and the spring retainer when the driven clutch and side gear splines are fully meshed.
13. Install the cover over the side gear and compress the springs. Make sure the side gear splines are completely meshed with the drive clutch splines.
14. Apply 9S3263 Threadlock to the internal threads of the flanged half case.
15. Place the assembly in a press and compress the springs. Install eight bolts and washers to secure the assembly.
16. Position the ring gear on the flanged half case. Install the bolts, nuts and washers. Tighten the nuts to a torque of 125-135 N·m (90-100 lb ft).
17. Press the differential bearing cones on the case halves.
18. Press the inner bearing on the pinion shaft.
19. Stake the bearing in four places equally spaced.
20. Press the center bearing onto the pinion shaft.
21. Position the center bearing cup and cage on the pinion shaft.
22. Position the bearing spacer (with the chamfer toward the threaded end of the shaft) and shims on the pinion shaft. Install the outer pinion bearing cone.
NOTE: If parts were replaced and new shims are provided, use one .25mm (.010 in) shim.
23. Install the original bearing cage shims and the pinion shaft assembly in the differential carrier housing. Use five identical oil seal retainer bolts and wahsers to pull the pinion shaft assembly fully into the carrier assembly. Be sure to align the oil holes as the bolts are tightened. Tighten to a torque of 170-190 N·m (125-140 lb ft).
24. Install the large pinion drop gear and nut. Block the gear to prevent turning, and tighten the pinion nut to a torque of 651-705 N·m (480-520 lb ft). Bearing preload should be 1-3 N·m (13-23 lb ft); if not, disassemble and add shims to decrease preload or remove shims to increase preload.
25. Attach a hoist to the differential and install into the carrier at an angle so that the ring gear will clear the inner bearing boss in the carrier.
26. Lift one side of the differential at a time and install a bearing cup and adjusting nut on both sides. Turn the adjusting nuts by hand to be sure of proper thread alignment.
27. Install the bearing caps and nuts on the bearings. Be sure to align marks made at disassembly. Do not tighten the nuts at this time.
28. Tighten the bearing adjusting nuts to adjust the bearings to zero end play.
29. Use a dial indicator to set backlash at 23-33 mm (.009-.013 in).
30. With the backlash set, tighten the opposite adjusting nut until the ring gear is difficult to move with two fingers. This sets the proper preload on the bearing.
31. After the backlash and preload adjustments have been made, check the tooth contact setting between the ring gear and the pinion as follows:
a. Put a small amount of marking compound (Prussian blue) on the ring gear teeth. Turn the pinion in both directions and compare the marks made with the correct tooth contact setting.
b. With no load, the correct tooth contact setting will be as shown. The correct area of tooth contact is located equally on both sides and starts near the toe of the gear and goes 30% to 50% up the length of the tooth. With this setting, when a load is put on the gear, the load will be over the correct area of the teeth.
c. If the piniion is too far away, short toe contact will result. To correct for this, remove shims in small increments. Check backlash and tooth contact each time until proper tooth contact is obtained.
d. If the pinion shaft is too near, a short heel contact will result. To correct this, add shims in small increments. Check backlash and tooth contact each time until proper tooth contact is obtained.
NOTE: Several adjustments of both pinion and bevel gear may be needed before correct tooth contact and gear clearance (backlash) is made. Always remember that a change to gear clearance will also change the tooth contact. Therefore, be sure to adjust the gear clearance before tooth contact is checked.
32. When proper tooth contact is made, remove the pinion shaft nut and large pinion gear. Remove the bolts and flat washers securing the pinion bearing cage to the differential carrier. Remove the pinion and cage assembly, coat both shim surfaces with 1U8846 Gasket Eliminator. Reinstall the shims, pinion and cage assembly on the carrier housing.
33. Tighten the differential cap bolts to a torque of 300-330 N·m (220-245 lb ft). Recheck the ring gear and pinion backlash. Recheck the differential bearings for proper preload.
34. Check the runout on the back face of the ring gear. Runout must not exceed .12 mm (.005 in) total indicator reading. If runout is excessive, remove the assembly and check for burrs or dirt under the mounting surface of the ring gear. Reassemble and recheck.
35. Apply a coat of 9S3263 Threadlock to the internal threads and install the adjusting nut lock with a bolt and lockwasher. Tighten to a torque of 34-38 N·m (25-28 lb ft).
36. Apply 5P3413 Pipe Sealant to the thrust screw threads. Adjust the clearance between the thrust screw and the ring gear to .26 - .38 mm (.010 - .015 in). Hold the thrust screw and tighten the nut. Be sure the indicator reading remains the same. Tighten the nut to a torque of 373 N·m (275 lb ft).
37. Apply 1U8846 Liquid Gasket to the carrier housing. Apply 9S3263 Threadlock to the threaded holes in the housing. Install the drop gear housing.
38. Install the drop gear housing bolts and tighten to a torque of 125-135 N·m (90-100 lb ft).
39. Press the bearing on the small gear and position in the drop gear housing.
40. Position the large drop gear on the pinion shaft with the long hub of the gear toward the pinion bearing.
41. Install the pinion shaft nut. Block the gears to prevent turning and tighten the nut to a torque of 495 N·m (365 lb ft).
42. Install the small gear outer bearing.
43. Apply 1U8846 Liquid Gasket to the drop gear housing machined surface. Apply 9S3263 Thread Lock to the threaded holes.
44. Position the drop cover on the drop gear housing.
45. Locate the drop gear housing cover dowels in the dowel holes, but do not drive them in at this time.
46. Start all of the drop gear cover housing bolts and tap the dowels in position.
47. Tighten the drop gear cover bolts to a torque of 125-135 N·m (90-100 lb ft).
48. Install the spindle on the axle end. Tighten the bolts to a torque of 410-450 N·m (300-330 lb ft).
49. Align the wheel hub with the spindle end, taking care not to damage the oil seal. Position the hub assembly on the spindle.
50. Install the internal gear and hub assembly into the wheel hub and on the spindle end splines.
51. Install the internal gear hub washer and wheel bearing adjusting nut.
52. Tighten the wheel bearing adjusting nut to about 677.9 N·m (500 lb ft) while rolling the wheel. Strike the rim and surrounding parts with a mallet to seat the bearings. Reverse the adjusting nut and strike again. Loosen the adjusting nut until there is slight bearing end play.
53. Tighten the adjusting nut to achieve a rolling torque of 9.5-16.2 N·m (7-12 lb ft) (new bearings) or 4.1-6.7 N·m (3-5 lb ft) (used bearings) higher than a no load running torque. It is best to use a low preload value because it may increase when the lock nut is installed.
54. Install the adjusting nut lock and lock nut. Tighten the lock nut to a torque of 677.9 N·m (500 lb ft). Bend two tangs of the lock over on each nut.
55. Coat the inside of the planetary pinion with grease to retain the pinion needle rollers.
56. Position assembled pinion and two pinion thrust washers in planetary spider assembly, making sure the tangs on the thrust washers engage the grooves in the spider.
57. Align the pinion shaft lock ball with the notch in the planetary carrier. Press the shaft into position being careful not to disturb the rollers in the pinion gear. Press the end of the shaft flush or slightly below the face of the carrier.
58. Coat the wheel hub to planetary carrier surface with 3S6252 Silicone Adhesive/Sealant. Attach a hoist to the planetary carrier and install on the wheel hub. Install the bolts and tighten to a torque of 125-135 N·m (90-100 lb ft).
59. Install the axle shaft in the housing. Install the sun gear and secure with the retaining ring. Align the axle shaft splines with the splines in the differential side gear. Align the sun gear with the planet gears.
60. Apply 3S6252 Silicone Adhesive/Sealant to the planetary cover. Bolt the cover to the planetary carrier and tighten the bolts to a torque of 54-61 N·m (40-45 lb ft).
61. Refill the axle with the proper lubricant.
End By:
a. install axle