Usage:
1. Remove the tires.
2. Disconnect and cap four lines (1) to the axle motor and one to the axle housing.
3. Using a hoist attached to the axle, remove four bolts (2) and lower the axle onto the dolly. Carefully slide the axle out from under the machine.
4. Secure the axle balanced on the dolly by use of a strap or chain.
5. Support the axle case with a hoist. Remove bolts (3) and the axle case. The weight of the axle case is 23 kg (50 lb).
6. Remove differential (4) from the housing.
7. Remove two bearings (5) with tooling (A).
8. Remove bolts (7) and lock plate (6)
9. Using a press, remove crown wheel (8) with tooling (B).
10. Remove axle gear (9) and both outer and inner clutch disc (10).
11. Drive out locking pin (11), (the location of the pin is shown, the pin is not visible). Remove differential axle (12) and three bevel gears (13).
12. Remove four bolts (14) and axle motor (15).
13. Remove bolts (16) and cover (17).
14. Remove cup springs and shims (18).
15. Press piston (19) out of and remove from the plate carrier using compressed air. Remove the outer and inner clutch disc behind the piston.
16. Remove plate carrier (20).
17. Unlock tab washer (21) and remove nut (22). Remove output gear (23) from the bevel pinion.
18. Remove oil collection plate (24)
19. Loosen screws (25) and remove gear box (26). The weight of the gear box is 23 kg (50 lb).
20. Using a press, remove pin (27) from the housing. Remove the reverse gear together with the thrust washers and needle bearings.
21. Using tooling (D), remove bevel pinion gear (28).
22. Using tooling (D), remove bearing (29).
Install Axle Assembly
1. To determine the appropriate shim thickness, perform the following and record the values obtained:
a. Insert tool (A) into the bore of the differential bearing in the axle housing as shown. Determine dimension "A" from the plane surface to the middle of the measuring cylinder. Example: A = 153.95 mm (6.0610 in).
b. Measure dimension "B" from the plane surface (housing shaft), to the contact bearing outer race of the drive pinion bearing, (inside), with tool (A). Example: B = 43.30 mm (1.7047 in).
c. Measure the bearing width. Example: Bearing width is "C" = 25.40 mm (1.00 in).
d. Record the dimension etched on the drive pinion (1) as "E". Example: E = 84.10 mm (3.311 in).
e. Shim thickness equals "F". To solve for "F", F = [A - (B+C)] = D; D -E = F (shim thickness).
Example: 153.95(A) - 68.70 (B + C) = 85.25 (D) 85.25 (D) - 84.10 (E) = 1.15 (F)
Illustration of the set-up of tooling B with the bearing.
2. Install determined thickness of shims.
3. Install the bearing outer race using tooling (B) to pull it into place.
4. Install the second bearing outer race firmly against the shoulder using tooling (C).
5. Heat bearing inner race (2). Install bearing inner race (2) on the drive pinion.
6. Install tool (D) on the drive pinion collar.
7. Install drive pinion assembly (3) with tool (D). Install heated bearing inner race (4) firmly against the shoulder.
8. Install spur gear (5) over the splines of the drive pinion and place it firmly against the shoulder.
9. Install the washer and nit (6).
10. Tighten nut (6) by continuous rotation of the drive pinion until a rolling resistance of 1 to 2 N·m (1 lb ft) has been obtained. Use tool (E).
11. Remove nut (6) and the washer. Remove spur gear (3) from the drive pinion.
12. Remove drive pinion (3) and tool (D) from the drive pinion.
13. To determine the correct spacer thickness, (X), required for assembly, measure the the width of tool (D) and the roll pin. There are three roll pins. The roll pins should be spaced 120° apart from each other. Measure each of the three pin locations for (X) and take an average of the three measurements.
14. Install the proper spacer (7) on the drive pinion collar.
15. Install the drive pinion. Install the heated inner bearing race firmly against the shoulder and guide spur gear (3) on the splines of the drive pinion. Install the washer and nut (6). tighten the nut to 350 N·m (260 lb ft).
16. Check the rolling resistance with tool (E). The rolling resistance should be 1 to 2 N·m (1 lb ft). If the correct rolling resistance has not been obtained, spacer (7) will need to be readjusted.
17. Install the reverse gear together with the thrust washers and needle bearing (8) into the housing. Press into place.
18. Install housing (9) onto the axle housing. Install the twelve bolts and torque to 120 N·m (90 lb ft).
19. Install cover (10) and tighten the three bolts.
20. Install the spur gear on the drive pinion firmly against the shoulder. Keep spur gear (3) from rotating and tighten nut (6) until a rolling resistance of 1 to 2 N·m (1 lb ft) has been obtained.
21. Drive lock plate (11) firmly against the shoulder and lock at the two points provided.
22. Install disc carrier (12) against the housing making sure it is firmly seated against the shoulder. Fasten two screws to temporarily hold the disc carrier in place.
23. In plate pack (13) there are four driven plates and three drive plates. Install plate pack (13), alternating one driven plate and one drive plate.
24. Install the piston without the piston rings.
25. The thickness of the washers (shims), required for assembly is equal to [(A-B) - C]. Determine the thickness of the thrust washer required as follows:
a. Determine dimension "A" by measuring from the flange face the the piston using tool (A). Example 38.50 mm (1.517 in).
b. Determine dimension "B" by measuring from the contact surface of the cup springs to the flange facing using tool (A). Example 25.90 mm (1.0197 in).
c. Dimension "C" is the mounting dimension of the cup springs. Dimension "C" does not change. Example: "C" = 9.40 mm (0.3700 in).
d. Example: (A - B) - C = thickness of thrust washers. 38.50mm (A) - 29.50 mm (B) = 12.60 mm - 9.40 mm (C) = 3.20 mm thickness of thrust washers.
26. Install the cup springs, thrust washer and end cover (14). Install the bolts and tighten to a torque of 120 N·m (90 lb ft). Install flange (15) and tighten the nuts.
27. Assemble plate pack (16), alternating one driven plate and one drive plate. There are five driven plates and four drive plates. Start with a driven plate.
28. Install the thrust washer and differential gears into the differential case and secure with differential shaft (17).
29. Install plate pack (16), crown wheel side down. Press the plate pack in using even pressure.
30. Using tool (A), measure the distance to the differential axis from the face as illustrated. The distance should be 0.10 to 0.15 mm (0.0039 to 0.0059 in).
31. Measure the plate pack on the opposite side using a feeler gauge. The measurement should be between 0.10 to 0.15 mm (0.0039 to 0.0059 in). If necessary, adjust with the pressure plate.
32. Align the bores and install heated crown wheel (18).
33. Install screws (19) and tighten to a torque of 69 N·m (49 lb ft).
34. Properly locate and install locking plate (20) firmly against the shoulder.
35. Install heated bearings (21) as shown.
36. Install differential assembly (22) into the axle housing.
37. Install the bearing outer race of the differential bearing (the crown wheel side), into tool (F) and fasten with the bolts.
Illustration for example only.
38. Loosen bolts (23) to preload the cup springs. This will allow the adjustment of the differential bearing.
39. Bring the outer bearing race into position using a threaded spindle. Do not allow rotation.
40. Using a dial indicator at the crown wheel, measure the backlash. The backlash should be 0.10 to 0.15 mm (0.004 to 0.006 in). If the backlash is not within the allowable limits, correct with washer (shims), see Step 25.
41. The differential bearing must have a rolling resistance of 2 - 4 N·m (1 -3 lb ft). Rolling resistance of the differential bearing is adjusted by shim thickness. To determine the correct shim thickness, perform the following.
a. To determine dimension "B", measure from the flange facing to the bearing contact surface with tool (A). Example; B = 6.35 mm (0.2500 in).
b. To determine dimension "A", measure from the flange facing to the bearing contact surface in tool (F). Example; A = 7.30 mm (0.2874 in).
c. Dimension A, 7.30 mm (0.2874 in) - dimension B 6.35 mm (0.2500 in) = 0.95mm (0.0374 in). In order to obtain a rolling resistance of the differential bearing of 2 - 4 N·m (1 -3 lb ft), it is necessary to select a shim which is thicker 0.1 mm (0.004 in). The shim thickness therefore equals 1.05 mm (0.0413 in).
42. Install the correct number of shims, as determined in Step 41, and the bearing outer race into the axle housing.
43. Lift the differential assembly out of the axle housing using a hoist. Cover of the crown wheel teeth with paint, (Prussian blue or red lead) and install the differential assembly and the axle housing. Fasten it temporarily with a few bolts.
44. Rotate the wheel assembly several times in both directions. Remove the axle housing and the differential assembly.
Correct tooth contact (concave side).
Correct tooth contact (convex side).
Decrease pinion distance (concave side).
Decrease pinion distance (convex side).
Increase pinion distance (concave side).
Increase pinion distance (convex side).
45. Inspect the pattern of paint on the gear teeth. If the tooth contact pattern is not correct, an error has been made during the measurement of the pinion drive. Repeat Step 41.
46. Install the axle housing with bolts (24). Tighten the bolts to a torque of 190 N·m (140 lb ft).
47. Tighten bolts (23) to 120 N·m (90 lb ft).