Service Manual
Contents
1. 35 Remove clutch driver 24 32 Remove reaction plates 34 Clutch Driver Removal Remove snap ring 36 Case Half Removal e 5 y Remove bolts 37 SS aN C Be sure to mark case halves before separating case halves 39 washer as removed 25 Side Gears and Spider 38 Disassembly Wow p S y Remove side thrust washer 40 Inspect cross and gears for wear Replace as needed e Remove the cross and pinion assembly Mark the cross and diff body section for easy alignment during reassemble 42 Remove differential pinion gears one at a time and place with proper thrust washer 45 Clutch Piston Disassembly Install seal retainer Carefully apply air to hole in seal retainer to remove clutch piston 47 Passage must be free of dirt or damage 26 44 Remove side thrust washer 46 Passage must be free of dirt or damage 48 h piston Remove clutc 49 e Remove piston wave spring 51 Seal Retainer Disassembly Remove inner and outer lip seals 53 Remove flange nut 27 50 A mem EV SEN Remove inner and outer2. Shim as required Apply MS266 oil to both sides of clutch plates First install one friction plate and then one reaction plate repeat until all plates are installed Align all grooves in plates with grooves in diff clutch housing 4 SET RING amp PINION SEE CHART 16 DANA Differential Assembly Instruction Cont Instruction Drawing For Hydralock Differential Assemblies Pressure Test Procedure Air pressure test the pressure and tank port seals and system Port W amp V Apply 12 psi 83 kPa to pressure and tank ports simultaneously Allow stabilization period of 20 seconds min Lock off pressure and measure decay in 10 seconds Alternate decay period is 1 psi 69 kPa per 5 minutes Hydraulic pressure test the pressure port seals and system port W Apply 600 psi 4137 kPa to pressure port Place open tank line back to tank Allow stabilization period of 20 seconds min and release Reapply 600 psi 4137 kpa and monitor fluid for a one minute period Fluid flow rate is not to Exceed 75 gpm 2 83 pm TIGHTEN TO 300 360 LBF FT PRESSURE PORT LANA Backlash and Ring Gear Runout Instructions Tighten bearing adjusting nuts to achieve Zero Backlash Loosen the adjusting nut opposite the ring gear until it no longer contacts the differential assembly Tighten the nut on the ring gear side until the ring gear contacts the pinion and zero backlash is obtained Tighten the other adjusting nut unti
3. Press inner and outer bearing cups in cage 31 Place bearing cage on pinion install outer pinion bearing cone Press bearing into cage assembly 9 Seal Retainer Installation Use correct driver to install the grease seal and pinion seal 2 in the seal retainer 11 Pinion Cage Installation Py lt 1 i N C W 1 uL Apply Loctite 4515 to bearing cage shims and joining surfaces in a continuous bead Cover entire surface 32 Check adjust pinion bearing rolling torque following the procedure listed in the Assembly Instructions section pages 3 and 13 Pinion mounting distance must be set following the procedure on pages 14 and 15 Install thrust washer into pinion seal retainer 12 Install bearing cage shim 13 bw Ls Position pinion cage assembly in carrier housing 15 Apply Loctite 4515 to pinion bearing cage in a continuous bead across entire surface 17 Apply Loctite 4262 to seal retainer capscrews 33 14 Remove flange nut and flange 16 Install pinion seal retainer 18 in Install seal retainer capscrews 19 20 Torgue 7 capscrews to Torgue 1 capscrew to 74 81 LBF FT 177 199 LBF FT 240 270 Nm 100 110 Nm
4. 82 my Ji Apply Loctite 4620 to outer lip seal 83 Apply Loctite 4620 to seal retainer 44 Using proper driver install outer lip seal 84 S Lightly apply Loctite 620 to inner lip seal 85 86 Use proper driver to install inner lip seal Lubricate piston rings 87 88 90 Apply Loctite 4262 to capscrews Install capscrews 45 91 1 2 Nm 93 Install back up ring and then the sguare cut seal on fitting 95 Install fittings 46 92 Fitting Installation Ins tall O Ring on fitting 94 96 Tighten fittings to 15 LBF FT 20 Nm and install caps
5. lt pana gt SPICER Off Highway Products Service Manual Axle 42R Hydralock Differential ASM 0182 February 2003 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the Spicer Off Highway Products Extreme care has been exercised in the design and selection of materials and manufacturing of these units The slight outlay in personal attention and cost reguired to provide regular and proper lubrication and inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product it s principle of operation troubleshooting and adjustments It is urged that the mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is reguired only Spicer Off Highway Products approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the eguipment Spicer Off Highway products does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied or approved by Spicer Off Highway Products Important Always furnish the dis
6. 10 Loosen 4 cap bolts 12 Loosen 3 retainer screws 13 14 15 WARNING er d I A e Once the caps are removed the ring gear and differential assembly can roll out of the carrier housing 17 Seal Retainer Removal Remove seal retainer 21 18 Adjuster Removal cS N Loosen adjusters and remove 19 Differential Assembly Removal Remove differential assembly from housing 21 Case Half Disassembly 20 Note Empty holes must be aligned with pinion centerline before removal 22 23 Remove bearing cup opposite side 22 Edges of rings can cut fingers 24 Remove differential case seal 25 Ring Gear Removal Loosen and remove all ring gear nuts 27 Place wooden blocks under ring gear 29 Flanged Case Half Removal Remove flanged case half bolts 23 26 Remove all ring gear bolts with brass driver 28 Use rubber hammer to remove ring gear 30 Use rubber hammer to remove flanged case half Friction and Reaction Plate 31 Removal I Note Friction and reaction plates may fall out when flanged case half is removed 33
7. ae N W t N Js N d gt UEOMO Apply Loctite 4262 to case capscrews Install case capscrews n 37 43 Torgue to 74 81 LBF FT 100 110 Nm a 45 Install snap ring 47 Install first reaction plate Note Align reaction plate holes with holes in friction plate 38 44 Clutch Driver Reassembly Install clutch driver Note The five holes in the clutch housing 46 Friction and Reaction Plate Reassembly Install first friction plate Note Align plate holes with holes in clutch housing 48 Install all plates in order Note See assembly instructions page 16 49 Clutch Piston Reassembly Lubricate flange half case 51 Lubricate seals 39 50 Install piston wave spring 52 ER Install piston outer seal 54 n a 7 W n E p lt P b Y 7 AS BEENE Use rubber hammer to install clutch piston 55 Flanged Half Case Reassembly a So E dd JA Install bearing using press 57 59 cs wow o Torque capscrews to 44 48 LBF FT 60 65 Nm 40 56 Align marks and install flange half case onto clutch housing 58 Install capscrews 60 Install bearing and seal 6
8. If friction modifiers are used follow instructions on TSB 278E recommended and may reduce the life of the axle and void the warranty 75W DEG C 40 30 20 10 0 10 20 30 40 50 F 40 22 4 14 32 50 68 86 104 122 Rana LEFT HAND SPIRAL SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART KN MOVE PINION TOWARD 2 GEAR IN THIS DIRECTION 77 MOVE PINION AWAY FROM DEDENDUM MOVE GEAR AWAY FROM PINION IN THIS DIRECTION PINION IN THIS DIRECTION CONVEX SIDE USE THIS PAGE All contact bearings shown below are on Left Hand spiral ring gear the drive is on the convex side of the tooth Fig 1 Typical preferred bearing on both sides of tooth while under a light load Fig 2 Toe bearing on both sides of tooth gear set noisy To move bearing toward heel increase backlash within limits by moving gear away from pinion Fig 4 Low bearing on gear and high bearing on pinion Correct by pulling pinion away from gear increase mounting distance Fig 5 High bearing on gear and low bearing on pinion Correct by moving pinion toward gear decrease mounting distance Fig 3 Heel bearing on both sides of tooth gear set noisy and could result in early gear failure To move bearing toward toe decrease backlash within limits by moving gear toward pinion Backlash Backlash should be measured with a dial indicator rigidly mounted with the stem perpendicular to the tooth surface at the extreme heel Rana RI
9. ZA piston seals 52 Flange Disassembly 54 mc S Carefully remove flange with puller 55 Remove spacer O ring 57 Pinion Cage Removal 56 58 Remove bolts from seal retainer 59 Install flange and flange nut 28 Remove pinion seal retainer 60 Remove pinion cage assembly 61 Seal Retainer Disassembly Remove thrust washer 63 Pinion Cage Disassembly a Place pinion inside of press Press pinion inner and outer cones out of cage 65 Remove inner and outer bearing cups 29 62 Remove grease seal 64 Remove pinion seal 66 Pinion Disassembly Remove pinion bearing spacer 67 68 Press inner bearing off of pinion Check for wear on pinion and bearing Replace as reguired 30 Reassembly Pinion Reassembly Press inner pinion bearing on pinion Press inner pinion bearing cone onto pinion Note All parts must be lubricated prior to reassembly do not assemble dry Stake pinion and inner race four places egually around diameter Pinion Cage Reassembly Install pinion bearing spacer and 010 0254mm shim reuse old shim if reusing gear set
10. 2e 80 90 Lbs In 9 10 Nm 110 120 Lbs In 13 14 Nm 1 4 28 5 16 18 3 i 5 16 24 180 200 Lbs In 21 23 Nm 215 240 Lbs In 24 27 Nm eee 25 28 Lbs Ft 34 38 Nm 35 40 Lbs Ft 48 54 Nm 3 8 24 7 16 14 N 7 16 20 40 45 Lbs Ft 54 61 Nm 60 65 Lbs Ft 82 88 Nm 65 70 Lbs Ft 88 95 Nm 90 100 Lbs Ft 125 135 Nm 90 100 Lbs Ft 125 135 Nm 125 140 Lbs FT 170 190 Nm 9 16 18 de 125 140 Lbs Ft 170 190 Nm 175 190 Lbs Ft 240 260 Nm dia 220 245 Lbs Ft 300 330 Nm 300 330 Lbs Ft 410 450 Nm 3 914 330 360 Lbs Ft 450 490 Nm 475 525 Lbs Ft 645 710 Nm i1 475 525 Lbs Ft 645 710 Nm 725 800 Lbs Ft 985 1085 Nm iin 650 720 Lbs Ft 880 975 Nm 1050 1175 Lbs Ft 1425 1600 Nm 1 1 4 7 1 1 4 12 900 1000 Lbs Ft 1220 1360 Nm 1475 1625 Lbs Ft 2000 2200 Nm FASTENER TOROUE 8 8 Coarse Threaded Fasteners Coarse Threaded Fasteners Thread Size Torgue Thread Size Torgue Class 8 8 Class 10 9 8 MBXO 8 T8 M6X1 8 10 M6X1 12 14 MEX 25 20 25 MTOXT S 1045 MI2X TS 70 78 Mx 110 125 M16X2 170 190 Moox2s 34030 M24X3 580 050 MGox3s 11501300 M36X4 2000 2250 Coarse Threaded Fasteners SAE O Ring Thread Thread Size Torque Class 129 Nm ibm Size M5X0 8 8 10 71 88 3125 24 T M6X1 14 16 124 142 3750 24 Lb Ft 4375 20 M8X1 25 34 40 26 30 5000 20 14 18 10 13 Mixis 7075 52 55 Mii vsta 65 06 Miao 18020 133155 Mix 280320 207236 M20
11. 9 hardware where presently used in production On all axles being overhauled bolts should be identified as described above and torque value chart consulted for correct torque At Reassembly Apply Thread Locking Compound Where Noted Guidelines for application where to apply A On bolts capscrews and studs anchor end B On nuts apply compound to the male thread of the mating fastener Apply compound to coat the full length and circumference of thread engagement Remove excess compound from mating parts after fastener installation Rana RECOMMENDED LUBRICANTS FOR SPICER DRIVE AXLES Recommendations Extreme pressure gear lubricant is recommended for use in all drive steer and rigid drive axles except where explicitly stated differently by Spicer Off Highway Products Engineering Mineral Based Acceptable lubricants must meet API GL 5 MT or MIL PRF2105E qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below Synthetics Synthetic lubricants are recommended providing they meet API GL 5 MT 1 qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases This produces a thickening of the mineral oil at the contact point This increase in viscosity helps to ma
12. as metal filings contaminated oil or laping compound Inspection The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date Bearings Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lintless cloth or paper to protect them until installed Oil Seals Gaskets and Retaining Rings Replacement of spring loaded oil seals gaskets and snap rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing member should be handled carefully particularly when being installed Cutting scratching or curling under lip of seal seriously impairs its efficiency At reassembly lubricate lips of oil seals with Multipurpose Lithium grease Grade 2 MS107C Gears and Shafts If magna flux process is available use process to check parts Examine teeth and ground and polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth a
13. produce a proper tooth contact with the ring gear when it and the differential assembly are assembled and adjusted to proper backlash setting The function of the gauge is to measure the distance from the centerline of the differential bearing bores to the ground surface on the end of the pinion gear This measurement when subtracted from the value etched on the ring gear will indicate the size of the shim pack required to position the pinion gear in proper relation to the ring gear On the outer diameter of the ring gear a ring gear to pinion mounting distance value will be etched Add half the thickness of the gauge bar Record this value This value may be different on each ring and pinion set due to manufacturing variations Insert a 4 base 5 32 diameter extension depth micrometer and 5 6 extension into the guide bore of the micrometer arbor Xt L r Paint bearing surfaces of carrier housing Mount adapter discs on micrometer arbor with gear tooth marking compound and set in position in carrier housing Do not contact any part of the carrier in this operation Apply pressure by hand and rotate adapter discs slightly to obtain a contact with bearing surfaces check for full bearing contact on bearing surfaces Pinion Mounting Distance Instructions If contact is full and proper position checking gauge assembly in carrier and check distance to ground surface on pinion Figure 4 DO NOT APPLY PRESSURE to arbor or micrometer Tu
14. 1 Ring Gear Reassembly Install ring gear 63 Note Leave four bolts out for pinion clearance k 4 ja 7 Apply Loctite 4262 to cap screws and install Leave 4 capscrews out 65 Torgue nuts 150 168 LBF FT 203 228 Nm 41 62 Use rubber hammer to seat ring gear flush Align holes in ring gear and case 64 Install nuts 66 Differential Assembly Note Four holes rotated to the bottom 67 68 69 71 Note See Assembly Instructions for backlash setting procedure and ring gear runout checking procedure See pages 16 and 18 42 70 _ Tighten lightly do not torgue 72 Cap Installation Apply Loctite 4262 to capscrews 73 Install caps and capscrews Torgue to 300 360 LBF FT 407 488 Nm Recheck backlash correct as needed 75 74 Apply Loctite 262 to adjusting lock capscrew and install 76 Torgue capscrew to 25 28 LBF FT 34 38 Nm 77 at x Install capscrews and nuts 43 Rotate empty ring gear holes to the top 78 BF FT Torque nuts 150 168 203 228 Nm 79 81 80 Seal Retainer Installation Apply Loctite 4262 to seal retainer
15. 21 Flange Reassembly 22 j of dri Install V Ring seal onto flange Pu em arive 34 25 26 Apply Loctite 4515 to pinion threads 27 N Run nut down then torque flange nut to 600 LBF LB 815 Nm Install flange nut 28 Side Gear and Spider Reassembly ON g Install Side thrust washer 30 Lubricate clutch side gear and install 35 Grease differential Cross Note If new parts are not being used the cross must be assembled using the numbering system as 31 directed in disassembly process Position inner needle roller bearing spacer on differential spider 33 32 Using a rubber band to facilitate assembly install one row of needle roller bearings 34 Install center roller bearing spacer 35 Position pinion gear on needles as shown Remove first rubber band Slide pinion gear over second row of needles remove second rubber band 36 Using another rubber band install outer row of needle roller bearings 36 pinion thrust washer 37 38 Align marks on plain half case wit mark on flanged half case Install plain half case Install side thrust washer 41 42 M CIS t3 PI
16. GHT HAND SPIRAL SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART K MOVE PINION TOWARD 2 GEAR IN THIS DIRECTION 772 MOVE PINION AWAY FROM DEDENDUM MOVE GEAR AWAY FROM PINION IN THIS DIRECTION PINION IN THIS DIRECTION CONVEX SIDE USE THIS PAGE All contact bearings shown below are on Right Hand spiral ring gear the drive is on the convex side of the tooth Fig 1 Typical preferred bearing on both sides of tooth while under a light load Fig 2 Toe bearing on both sides of tooth gear set noisy To move bearing toward heel increase backlash within limits by moving gear away from pinion Fig 4 Low bearing on gear and high bearing on pinion Correct by pulling pinion away from gear increase mounting distance Fig 5 High bearing on gear and low bearing on pinion Correct by moving pinion toward gear decrease mounting distance Fig 3 Heel bearing on both sides of tooth gear set noisy and could result in early gear failure To move bearing toward toe decrease backlash within limits by moving gear toward pinion Backlash Backlash should be measured with a dial indicator rigidly mounted with the stem perpendicular to the tooth surface at the extreme heel nd FASTENER TOROUE Grade 5 Indentification 3 Radial Grade 8 Identification 6 Radial Dashes 120 Degrees Apart on Head of Bolt Dashes 60 Degrees Apart on Head of Bolt Grade 5 Fastener Size Lubricated and Plated Lubricated and Plated 14
17. al Flange Half Case Case Washer Case Capscrew Case Plug Piston Rings Rotary Seal Gear Nut Inner Pinion Bearing Pinion Gear Differential Carrier and Cap Assy Differential Adjusting Nut Not Used In This Model Adjusting Nut Washer AN DESCRIPTION Adjusting Nut Capscrew Lip Seal Inner Seal Retainer Plug Cap Screws Seal Retainer Lip Seal Outer Nipple O Ring Nipple Back Up Ring Tank Port Sguare Cut Seal Tank Port Back Up Ring Pressure Port Cap Cap Pressure Nipple Nipple O Ring Seal Sguare Cut Pressure Port Plug Inner Pinion Bearing Cone Inner Pinion Bearing Cup Pinion Bearing Spacer Kit Bearing Cage Shim 007 Bearing Cage Shim 010 Pinion Bearing Cage Assy Outer Pinion Bearing Cup Outer Pinion Bearing Cone Pinion Seal Not Used In This Model Pinion Seal Retainer Grease Fitting Seal Retainer Lockwasher Seal Retainer Capscrew Seal Retainer Lockwasher Seal Retainer Capscrew Grease Seal Thrust Washer Not Used In This Model V Ring Seal Not Used In This Model Flange O Ring Spacer O Ring Flange Nut Differential Case Assy Differential Body Assy Drive Gear and Pinion Set O lt Install bearing cage and pinion shaft assembly in differential carrier without bearing cage shims Use 4 oil pinion seal retainer bolts with flat washers to pull pinion shaft assembly fully into carrier assembly Make sure oil passages are aligned Install 3 flat washers on each bolt to prevent them f
18. intain lubricant film thickness reducing the possibility of surface and spalling fatigue Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so Before using a synthetic lubricant in heavy applications the customer must check with the lubricant supplier on the issue of high pressure lubricant applications Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Extended Oil Change Interval Extended oil service may result when using synthetic lubricants Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a baseline Wear metal analysis can provide useful information but an axle should not be removed from service based solely on this analysis Vehicles which are prone to high levels of ingested water in the axle or water as a result of condensation should not use extended drain intervals Friction Modifiers Friction modifiers may be used with the lubricant to reduce Posi Torg limited slip differential noise or liquid cooled brake noise
19. l snug Mount a dial indicator as shown in the photo plunger contacting the gear tooth Set backlash by loosening adjuster on ring gear side then alternately tightening the other adjuster Gently rock ring gear back and forth while observing the dial indicator reading Compare the dial indicator reading against the specs found in the Assembly Instructions section page 16 Continue procedure until proper spec is obtained Once proper backlash has been obtained tighten adjusting nut opposite ring gear to set bearing preload Using only thumb and forefinger move ring gear back and forth When ring gear becomes difficult to move bearing preload has been set Use dial indicator to check back face of ring gear Rotate at least one full turn Runout must not exceed 005 0 12mm total indicator reading If runout is excessive remove assembly and check for burrs or dirt under mounting surface of ring gear Reassemble and recheck Disassembly 1 Ring Gear Bolt Removal N LR Loosen 4 ring gear nuts K 2 Carefully remove the 4 bolts with a brass driver 5 Fitting Removal Remove fitting caps 19 Rotate the ring gear until the empty holes align with the pinion Loosen fittings Remove fittings Remove 4 cap bolts 20 8 Cap Removal de E Loosen lock bolt
20. of Contents Foreword Caution Cleaning and Inspection Recommended Lubricants Torque Limits and Specifications Pinion Staking Exploded View Parts Description Pinion Bearing Rolling Torque Instructions Pinion Mounting Distance Instructions Differential Assembly Instruction Backlash and Ring Gear Runout Instructions Disassembly Ring Gear Bolt Removal Fitting Removal Cap Removal Seal Retainer Removal Adjuster Removal Differential Assembly Removal Case Half Disassembly Ring Gear Removal Flanged Case Half Removal Friction and Reaction Plate Removal Clutch Driver Removal Case Half Removal Side Gear and Spider Disassembly Clutch Piston Disassembly Seal Retainer Disassembly Flange Disassembly Pinion Cage Removal Seal Retainer Disassembly Pinion Cage Disassembly Pinion Disassembly Reassembly Pinion Reassembly Pinion Cage Reassembly Seal Retainer Installation Pinion Cage Installation Flange Reassembly Side Gear and Spider Reassembly Case Half Reassembly Clutch Driver Reassembly Friction and Reaction Plate Reassembly Clutch Piston Reassembly Flanged Half Case Reassembly Ring Gear Reassembly Differential Assembly Cap Installation Seal Retainer Installation Fitting Installation DANA Sr CLEANING and INSPECTION Cleaning Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thor
21. oughly cleaned of all old lubricants and foreign materials Caution Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners Bearings Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean When drying bearings use moisture free compressed air being careful to direct air stream across bearings as to avoid spinning Bearings may be rotated slowly by hand to facilitate the drying process Housing Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner Caution Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners Thoroughly dry all parts cleaned immediately by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such
22. re cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone Inspect shafts to make certain they are not sprung bent or splines twisted and that shafts are true Differential pinions and side gears must be replaced as sets Differential ring gear and spiral pinion must also be replaced as a set if either is damaged CLEANING and INSPECTION Cont Housing and Covers Inspect housing covers planet spider and differential case to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condition which cause subsequent oil leaks or failures Reassembly of Axle The reassembly instructions describe the procedure to be followed when reassembling and installing components of axle Instructions covering reassembly of opposite side is identical unless otherwise noted Important Class 8 8 and 10 9 and 12 9 fastening hardware has been used in the production of he axle assemblies covered in the manual A table of proper torque values for the fastener classes above are provided within this manual The class of hardware may be determined by the markings contained of the head of each capscrew Class 12 9 torque values needs to be used on all sockethead capscrew used with this assembly Torque values specified in text of this manual are for class 8 8 10
23. rn micrometer carefully and evenly until tip of extension contacts the ground surface of the pinion In the assembly shown the distance measures 5 159 inches the reading on the micrometer being 159 inch Subtract this reading from the value etched on the ring gear this eguals the amount of shims to be added between the pinion bearing cage and the carrier housing Example 5 159 Value etched on ring gear and half the thickness of the gauge bar 5 129 Initial micrometer reading 030 Add this value in shims Remove bolts holding pinion bearing cage in differential carrier and remove bearing cage and pinion assembly Install required shim pack and reinstall cage and pinion assembly in carrier Tighten cage screws 177 199 LBF FT 240 270 Nm temporarily After adding required amount of shims again mount checking gauge assembly and recheck reading The reading should now be 159 5 159 inches plus or minus 002 inch In other words the reading should be equal to value etched on the ring gear within 004 inch Rana Differential Assembly Instruction 1 Apply Loctite 262 2 3 Select spacer to obtain a pinion bearing rolling torque of Apply Loctite 515 13 23 LBF IN 1 5 2 6 Nm with pinion assembled in carrier This check to be made before differential is assembled and not to include pinion oil seal drag Differential assembly to be adjusted to obtain a backlash of 010 254 mm to 014 355 mm between ring gear and pinion
24. rom bottoming Temporarily install companion flange on end of pinion shaft without installing pinion oil seal retainer Install companion flange retaining tool on companion flange and torgue flange nut to 600 LBF LB 850 Nm Remove companion flange retaining tool and use inch pound torgue wrench to check bearing preload If bearing preload is not between 13 and 23 LBF IN 1 3 Nm the flange will have to be removed and the cage disassembled Shims can then be added or removed as needed to obtain proper reading Add shims to increase preload remove shims to reduce preload Reassemble unit and check again 13 z A Pinion Mounting Distance Instructions A pinion setting gauge must be used to achieve a precise mounting distance between the ring and pinion The use of the gauge will determine the amount of shims needed to achieve the proper mounting distance The shims will be placed under the pinion bearing cage to achieve an exact mounting distance between the ring gear and pinion By using the gauge and adding the proper thickness of shims an optimum tooth contact will be obtained Setting the ring and pinion mounting distance without the gauge will require a trial and error procedure A shim must be installed under the pinion bearing cage and then the unit must be completely assembled per service manual instructions The procedure must be repeated until proper tooth contact is obtained The position of the pinion as described will
25. tributor with the serial and model number when ordering parts CAUTION To reduce the chance of personal injury and or property damage the following instructions must be observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are reguired the part must be replaced with one of the same part number or with an eguivalent part Do not use a replacement part of lesser guality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures reguire the use of tools specifically designed for the purpose Accordingly anyone who intends to use a replacement parts service procedure or tool which is not recommended by SOHPD must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the unit or render it unsafe It is also important that these Cautions and Notices are not exhaustive because it is impossible to warn of all the possible hazardous consequences that might result from failure to following these instructions ECT Table
26. x25 550600 406443 M24X3 900 1050 664 774 1 6250 12 102 115 75 85 M30X3 5 1850 2100 1364 1549 1 8750 12 102 115 75 85 M36X4 3250 3700 2397 2729 NOTE Socket head capscrews are all Class 12 9 9 lt a NN PINION STAKING Staking of the pinion end to the inner pinion is reguired when the inner pinion bearing or the pinion shaft and ring gear are being replaced If a staking groove is in the pinion shaft use procedure shown in Figure A and a sguare end staking tool If pinion has no staking groove use procedure in Figure B and a standard prick punch to up set the metal over the bearing inner race FIGURE A OPTIONAL CONSTRUCTION NO STAKING GROOVE FIGURE B STAKE IN 6 PLACES EXPLODED VIEW EI DIFFERENTIAL ASSEMBLY DESCRIPTION DESCRIPTION Not Used In This Model Adjusting Nut Lockwasher Adjusting Nut Capscrew Differential Adjusting Nut Differential Bearing Cup Differential Bearing Cone Differential Case Seal Carrier Cap Washer Carrier Cap Capscrew Case Capscrew Case Washer Plain Half Case Side Thrust Washer Side Gear Pinion Gear Thrust Washer Pinion Gear Needle Roller Thrust Washer Pinion Needle Rollers Needle Roller Thrust Washer Differential Cross Clutch Side Gear Side Thrust Washer Ring Gear Capscrew Ring Gear Clutch Housing Clutch Driver Snap Ring Driver Friction Plate Reaction Plate Clutch Plate Piston Outer Seal Piston Inner Seal Piston Wave Se
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