Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 220-8428 | Spanner Wrench | 1 |
B | 220-8430 | Pinion Wrench | 1 |
C | 202-7965 | Adjusting Tool Gp | 1 |
E | 1P-0520 | Driver Gp | 1 |
F | 235-2790 | Pinion Setting Tool | 1 |
G | 235-2792 | Differential Setting Tool | 1 |
H | 6V-2012 | Depth Micrometer | 1 |
J | - | Loctite 270 | 1 |
K | - | Loctite Anaerobic Gasket Flange | - |
L | 8T-5096 | Dial Indicator Gp | 1 |
- Lower the temperature of bearing cups (61). Use Tooling (E) to install bearing cups (61) into the center housing.
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Illustration 2 g06048362 - Install bearing cones (54) and (59) along with Tooling (F).
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Illustration 3 g06048654 - Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) and temporarily install bolts (28). Repeat for the opposite side.
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Illustration 4 g03784062 - Install Tooling (G) into the center housing. Make sure that Tooling (G) is inserted into both brake cylinders.
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Illustration 5 g03784067 Show/hide tableIllustration 6 g03784071 - Use Tooling (H) to measure Distance (A). Distance (B) equals
145 mm (5.7 inch) . Distance (C) equals50 mm (2.0 inch) . Use the following formula to calculate Measurement (X): A + C - Bmm = X. Record Measurement (X).Show/hide tableIllustration 7 g06048369 - Measurement (V) is stamped on the head of pinion shaft (56). Use the following formula to calculate Measurement (S): X - V (Stamped on Pinion Head) = S.
- Among the available list of shims, choose the shim with the thickness of Measurement (S).
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Illustration 8 g06048663 - Remove Tooling (G). Remove brake cylinder assemblies (27). Remove the nut and the washer from Tooling (F) and remove Tooling (F). Remove bearing cones (54) and (59).
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Illustration 9 g06048389 - Install the suitable shim (55) onto pinion shaft (56). Install shim (55) with the chamfer against the gear. Raise the temperature of bearing cone (54) and install bearing cone (54) onto pinion shaft (56). Seat bearing cone (54) firmly against shim (55).
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Illustration 10 g06048399 - Install washers (57) and collapsible spacer (58) onto pinion shaft (56).
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Illustration 11 g06048406 - Install pinion shaft (56) into the center housing. Raise the temperature of bearing cone (59) and install bearing cone (59) onto pinion shaft (56).
- Install the lock washer and the ring nut on pinion shaft (56).
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Illustration 12 g06047672 - Use Tooling (A) and Tooling (B) to tighten locknut (52). Use Tooling (B) with a dial type torque wrench to set the rotating torque. Tighten lock nut (52) to achieve a rotating torque of
4.13 N-m to 4.46 N·m (36.6 lb in to 39.5 lb in) .Show/hide tableIllustration 13 g03281998 - Use a suitable hammer and a punch and stake ring nut (32) into the keyway groove.
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Illustration 14 g03652883 - Install washer (52), O-ring seal (49). Install seal ring (53) to a depth of
7.5 ± 0.5 mm (0.295 ± 0.020 inch) from the face of housing.Note: Seal ring (53) is to be installed after the rolling torque has been set.
- Install yoke (50) and retaining ring (51).
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Illustration 15 g03652894 - Install thrust washer (37) and sun gears (35). Install thrust washers (38), spider gears (34), and shafts (36) into differential housings (33) and (39).
- Raise the temperature of bearing cones (32) and (40). Install bearing cones (32) and (40).
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Illustration 16 g06048739 - Install bevel gear (31) onto the differential housing. Apply Tooling (J) to the threads of bolts (30). Install bolts (30). Tighten bolts (30) to a torque of
180 N·m (133 lb ft) .Show/hide tableIllustration 17 g06048777 Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
- Apply a thin coat of grease onto O-ring seals (21) and (22). Install the O-ring seals onto brake piston (23).
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Illustration 18 g03262499 - Install shaft (20), and cam (15).
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Illustration 19 g03259668 - Install cam, using the alignment marks made while disassembling cam (15) with the pin (16).
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Illustration 20 g03262498 - Install O-ring seal (19).
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Illustration 21 g03259666 Show/hide tableIllustration 22 g03262497 Show/hide tableIllustration 23 g03262496 - Install spacer (11) and washer (12).
- Install steel ball (18). Install shaft screw (17).
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Illustration 24 g03259667 - Install bracket (14) and bolts (13).
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Illustration 25 g03259658 - Install lever (8) using the previous alignment mark on the lever (8) and shaft (9).
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Illustration 26 g03259652 - Install adjusting screw (5) and tighten lock nut (4).
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Illustration 27 g03259655 - Install bolt (6) and washer (7).
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Illustration 28 g06048784 - Install brake piston (23) into brake cylinder assembly (27). Make sure that the holes on brake piston (23) align with the holes in brake cylinder assembly (27). Make sure that the brake piston (23) is installed all the way to the bottom of brake cylinder assembly (27). If necessary, tap brake piston (23) with a rubber mallet to install brake cylinder assembly (27) completely to the bottom.
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Illustration 29 g06048794 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install springs (24) and the bolts. Install bolts (25). Tighten bolts (25) to a torque of
13 N·m (115 lb in) . Tighten springs and bolts (24) to a torque of13 N·m (115 lb in) .Show/hide tableIllustration 30 g06048833 - Position brake cylinder assembly (27) on a flat surface. Use Tooling (E) to install bearing cup (48).
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Illustration 31 g06045860 - Use Tooling (C) and install spanner nut (45) into brake cylinder assembly (27).
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Illustration 32 g06048881 - Apply Tooling (K) to the mating surfaces of the center housing and the left brake cylinder assembly (27). Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) onto the opposite side of the bevel gear in the center housing. Install bolts (28). Tighten bolts (28) to a torque of
79 N·m (58 lb ft) .Show/hide tableIllustration 33 g06047649 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
- Position fork (68) into the center housing. Install rod (69), spring (70), bushing (71), retaining ring (72), O-ring seals (73), piston (74), O-ring seal (75), and cover (76). Apply Tooling (G) to the threads of bolts (77) and install bolts (77). Install retaining ring (67), washer (66), spring (65), O-ring seal (64), and cover (63). Apply Tooling (J) to the threads of bolts (62) and install bolts (62). Tighten bolts (62) and (77) to a torque of
27 N·m (239+ lb in) .Show/hide tableIllustration 34 g01029529 - Install the differential into the left side of the center housing.
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Illustration 35 g06048917 - Apply Tooling (K) to the mating surfaces of the center housing and the right brake cylinder assembly (27). Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) onto the center housing and install bolts (28). Tighten bolts (28) to a torque of
79 N·m (58 lb ft) . Use Tooling (A) and install spanner nut (45).Show/hide tableIllustration 36 g01029534 - Oscillate the pinion shaft while using Tooling (A) to advance the spanner nuts until there is slight backlash with no end play.
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Illustration 37 g01038165 Note: Typical example.
- Install a dial type torque wrench onto the pinion shaft. Measure the total rotating torque. Use Table 2 to determine the total rotating torque (TRT).
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Table 2 PINION BEARINGS AND DIFFERENTIAL BEARINGS PRELOAD TABLE BEVEL GEAR RATIO No. of PINION TEETH No. of BEVEL TEETH ALL PRELOAD MUST BE MEASURED WITH PINION SEAL 11 32 REFERENCE DIA. 44.6 mm (1.76 inch) PINION BEARING PRELOAD TOTAL PRELOAD (PINION BEARING PRELOAD + BEVEL GEAR BEARINGS PRELOAD TORQUE MINIMUM TORQUE MAXIMUM TORQUE 4.13 N·m (36.50 lb in) 4.68 N·m (41.39 lb in) 4.95 N·m (43.83 lb in) 4.13 N·m (36.56 lb in) 4.68 N·m (41.42 lb in) 4.96 N·m (43.86 lb in) 4.15 N·m (36.73 lb in) 4.70 N·m (41.60 lb in) 4.975 N·m (44.03 lb in) 4.20 N·m (37.17 lb in) 4.75 N·m (42.04 lb in) 5.03 N·m (44.48 lb in) 4.25 N·m (37.62 lb in) 4.800 N·m (42.48 lb in) 5.08 N·m (44.92 lb in) 4.30 N·m (38.06 lb in) 4.85 N·m (42.93 lb in) 5.125 N·m (45.36 lb in) 4.35N·m (38.50 lb in) 4.90 N·m (43.37 lb in) 5.18 N·m (45.80 lb in) 4.40 N·m (38.94 lb in) 4.95 N·m (43.81 lb in) 5.23 N·m (46.25 lb in) 4.46 N·m (39.47 lb in) 5.0 N·m (44.34 lb in) 5.29 N·m (46.78 lb in) - If, the total rotating torque (TRT) is less than the specified amount tighten both spanner nuts equally. If the total rotating torque (TRT) is greater than the specified amount, loosen both spanner nuts equally. Always maintain slight backlash.
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Illustration 38 g03784185 Note: Typical example.
- Mount Tooling (L) onto the center housing. Measure the backlash between the pinion and the bevel gear. The proper backlash setting is
0.180 mm to 0.230 mm (0.007 inch to 0.009 inch) .Show/hide tableIllustration 39 g01449257 - If the backlash is not within the specification, retract one spanner nut and advance the opposite spanner nut equally order to 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 40 g06048995 - Install retainer (46) and bolt (47) into both brake cylinder assemblies (27). Tighten bolts (47) to a torque of
13 N·m (115 lb in) .Show/hide tableIllustration 41 g03642506 Note: There is a raised shoulder on brake hub (3). Ensure that the raised shoulder on the brake hub is positioned toward the axle housing.
- Place drive plates (1) between brake disc (2). Make sure holes in brake discs (2) are in alignment for cooling purposes.
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Illustration 1 | g06048316 |
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- Install the axle housing.