415F2 Industrial Loader Power Train Axle Housing (Differential and Bevel Gear) (Front) - Assemble Caterpillar

Assembly Procedure

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g01517459

1. Lower the temperature of bearing cups (31) and (32). Use Tooling (E) to install bearing cups (31) and (32).
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   Illustration 2	g01517493

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   Illustration 3	g01517411

2. Install bearing cone (33) onto Tooling (F). Install Tooling (F) into differential housing (8). Install bearing cone (29), washer (24), and nut (22). Tighten nut (22) until there is no end play.

3. Install Tooling (G) and Tooling (H). Install caps (5) and bolts (4). Install Tooling (J).

4. Use Tooling (G), Tooling (H), and Tooling (J) to measure the distance to the pinion.

5. Measure the depth from Tooling (H) to the bottom of the hole in Tooling (F). Record the measurement as Measurement (X).
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   Illustration 4	g01517533

6. Measurement (V) is stamped on the head of pinion shaft (30). Measurement (S) is the thickness of the shim that is used between pinion shaft (30) and the bearing cone. Use the following formula to calculate Measurement (S): X mm - V mm = S mm.

7. Among the available list of shims, choose the shim with the thickness of Measurement (S).
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   Illustration 5	g01517553

8. Remove bolts (4), caps (5), Tooling (G), and Tooling (H). Remove nut (22), washer (24), and bearing cone (29). Remove Tooling (F) and bearing cone (33).
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   Illustration 6	g02963345

9. Install shim (34) onto pinion shaft (30). Install shim (34) with the chamfer against the gear. Raise the temperature of bearing cone (33). Install bearing cone (33) onto pinion shaft (30).
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   Illustration 7	g02971396

10. Raise the temperature of bearing cone (29). Install pinion shaft (30), washers (27), collapsible spacer (28), and bearing cone (29).
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    Illustration 8	g01517453

11. Install lip seal (26) to a depth of 13.5 mm (0.53 inch) from the surface of differential housing (8).
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    Illustration 9	g01517573

    Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.

12. Install yoke (23). Install O-ring seal (25), washer (24), and nut (22).
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    Illustration 10	g01517595

13. Use Tooling (C) with a dial type torque wrench to set the rolling torque. Tighten nut (22) to achieve a rolling torque of 1.8 N to 2.6 N·m (15 lb in to 23 lb in).
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    Illustration 11	g01517429

14. Use a suitable hammer and a suitable punch to stake nut (22).
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    Illustration 12	g01517383

15. Install thrust washer (20) and side gear (21). Install gears (19) and thrust washers (18).
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    Illustration 13	g01517379

16. Install planetary shafts (17). Install locking pins (16). Install side gear (15) and thrust washer (14). Install cover (13).
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    Illustration 14	g01041480

17. Raise the temperature of bearing cone (9) and bearing cone (10). Install bearing cone (9) and bearing cone (10).
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    Illustration 15	g01040825

18. Install bevel gear (12) onto the differential. Apply Tooling (K) to the threads of bolts (11). Install bolts (11) and tighten bolts (11) to a torque of 70 N·m (52 lb ft).
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    Illustration 16	g01040808

19. Install bearing cups (6) and (7) and install the differential into axle housing (8).
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    Illustration 17	g01040715

20. Install caps (5) and install bolts (4). Slightly tighten bolts (4). Do not torque bolts (4) at this time.
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    Illustration 18	g01034579

21. Use Tooling (A) and install spanner nuts (3).

22. Oscillate the pinion shaft and use Tooling (A) to advance spanner nuts (3) until there is slight backlash and no end play on the bearings.

    Note: Use the following two Steps to set the proper bearing preload.

23. Use a dial type torque wrench and measure the total rotating torque. Use the following formula to calculate the total rotating torque (TRT): P equals the rotating torque that was measured in Step 13. TRT = P + 0.53 N·m (4.7 lb in) to P + 0.80 N·m (7 lb in)

24. If the total rotating torque (TRT) is less than the specified amount, tighten the spanner nuts. If the total rotating torque (TRT) is greater than the specified amount, loosen the spanner nuts. Always be sure to maintain a slight backlash.
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    Illustration 19	g02915396

25. Mount Tooling (L) onto the differential housing, as shown. Measure the backlash between the pinion and the bevel gear. The proper backlash setting is between 0.180 mm (0.0071 inch) and 0.320 mm (0.0126 inch).
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    Illustration 20	g01029595

26. If the backlash is not within the specification, retract one spanner nut and advance the opposite spanner nut equally. This procedure will maintain the bearing preload. If the backlash is less than the specified amount, move the bevel gear in Direction (A). If the backlash is greater than the specified amount, move the bevel gear in Direction (B).
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    Illustration 21	g01040713

27. Install retainers (2) and bolts (1). Tighten bolts (1) to a torque of 13 +1/ -6 N·m (115 +6 / / -40 lb in).
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    Illustration 22	g01034820

28. Tighten bolts (4) to a torque of 220 +11 / -33 N·m (162 +8/ -24 lb ft).

End By:

1. Install the front axle differential and bevel gear into the axle housing.