Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Assemble
Assembly Procedure
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| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 202-7965 | Spanner Socket | 1 |
| C | 1P-1859 | Retaining Ring Pliers | 1 |
| D | 235-2784 | Pinion Wrench | 1 |
| F | 1P-0520 | Driver Gp | 1 |
| G | 235-2790 | False Pinion | 1 |
| H | 235-2792 | False Differential | 1 |
| J | 6V-2012 | Depth Micrometer | 1 |
| K | - | Loctite 270 | 1 |
| L | 069-4707 | Sealant | 1 |
| M | 8T-5096 | Dial Indicator Gp | 1 |
- Use Tooling (F) and install bearing cups (58) into the center housing.
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| Illustration 1 | g01083339 |
- Install bearing cones (40) and (41). Install Tooling (G) .
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| Illustration 2 | g01083342 |
- Align the location marks that were made during the removal procedure. Position brake cylinder (4) and temporarily install bolts (9). Repeat for the other side.
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| Illustration 3 | g01024510 |
- Install Tooling (H) into the center housing. Make sure that Tooling (H) is inserted into both brake cylinders.
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| Illustration 4 | g01083545 |
- Use Tooling (J) in order to measure Distance (A). Distance (B) equals 145 mm (5.7 inch). Distance (C) equals 50 mm (2.0 inch). Use the following formula in order to calculate Measurement (X) : A mm + C mm - B mm = X mm. Record Measurement (X) .
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| Illustration 5 | g01047703 |
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| Illustration 6 | g01047705 |
- Measurement (V) is stamped on the head of pinion shaft (37). Use the following formula in order to calculate Measurement (S) : X mm - V mm = S mm.
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| Illustration 7 | g01047712 |
- Among the available list of shims, choose the shim with the thickness of Measurement (S) .
- Remove Tooling (H). Remove brake cylinders (4). Remove the nut and the washer from Tooling (G) and remove Tooling (G). Remove bearing cones (40) and (41) .
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| Illustration 8 | g01083546 |
- Install the suitable shim onto pinion shaft (37). Install the shim with the chamfer against the gear. Raise the temperature of bearing cone (41) and install bearing cone (41) onto pinion shaft (37) .
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| Illustration 9 | g01027392 |
- Install washers (38) and collapsible spacer (39) onto pinion shaft (37) .
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| Illustration 10 | g01033145 |
- Install pinion shaft (37) into the center housing. Raise the temperature of bearing cone (40) and install bearing cone (40) onto pinion shaft (37) .
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| Illustration 11 | g01083548 |
- Install seal (36) into the center housing.
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| Illustration 12 | g01083550 |
- Install brake disc (33), O-ring seal (34), washer (35), and nut (32) .
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| Illustration 13 | g01026413 |
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| Illustration 14 | g01047714 |
Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
- Use Tooling (D) with a dial type torque wrench in order to set the rotating torque. Tighten nut (32) in order to achieve a rotating torque of 4.10 N·m to 4.40 N·m (36.0 lb in to 39.0 lb in).
Note: Rotate brake disc (33) back and forth before measuring the rotating torque. Rotating brake disc (33) back and forth will allow the parts to settle. Rotating brake disc (33) back and forth will allow an accurate rotating torque measurement to be taken.
- Use a suitable hammer and a punch and stake nut (32) .
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| Illustration 15 | g01026410 |
- Install bushing (31) .
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| Illustration 16 | g01080976 |
- Install bushing (30) .
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| Illustration 17 | g01080974 |
- Install O-ring seals (17) onto pins (16). Install pins (16). Install collar (18) .
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| Illustration 18 | g01080968 |
Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
- Install thrust washer (28) and side gear (29). Install thrust washers (26) and gears (27) .
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| Illustration 19 | g01080972 |
- Install shafts (25). Install locking pins (24).
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| Illustration 20 | g01080971 |
- Install side gear (23) and thrust washer (22). Install cover (21) .
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| Illustration 21 | g01080970 |
- Raise the temperature of bearing cones (14) and (15). install bearing cones (14) and (15) .
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| Illustration 22 | g01029527 |
- Install bevel gear (21) onto the differential. Apply Tooling (K) to the threads of bolts (20). Install bolts (20) and tighten bolts (20) to a torque of 180 N·m (133 lb ft).
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| Illustration 23 | g01026263 |
- Apply a thin coat of grease onto O-ring seals (5). Install O-ring seals (5) onto brake piston (6) .
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| Illustration 24 | g01028682 |
Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
- Install brake piston (6) into brake cylinder (4). Make sure that the holes on brake piston (6) align with the holes in brake cylinder (4) .
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| Illustration 25 | g01028683 |
- Install springs and bolts (8). Install bolts (7). Tighten bolts (7) to a torque of 10 N·m (7 lb ft). Tighten springs and bolts (8) to a torque of 10 N·m (7 lb ft).
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| Illustration 26 | g01047720 |
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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. |
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- Position brake cylinder (4) on a flat surface. Use Tooling (F) and install bearing cup (13) .
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| Illustration 27 | g01028752 |
- Use Tooling (A) and install spanner nut (12) into brake cylinder (4).
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| Illustration 28 | g01028800 |
- Apply Tooling (L) to the mating surfaces of the center housing and the left brake cylinder (4). Align the location marks that were made during the removal procedure. Position brake cylinder (4) onto the center housing and install bolts (9). Tighten bolts (9) to a torque of 79 N·m (58 lb ft).
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| Illustration 29 | g01028802 |
- Position fork (48) into the center housing. Install shaft (49), spring (50), bushing (51), retaining ring (52), O-ring seals (53), piston (54), O-ring seal (55), and cover (56). Apply Tooling (K) to the threads of bolts (57) and install bolts (57). Install retaining ring (47), washer (46), spring (45), O-ring seal (44), and cover (43). Apply Tooling (K) to the threads of bolts (42) and install bolts (42). Tighten bolts (42) and (57) to a torque of 23 N·m (17 lb ft).
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| Illustration 30 | g01081439 |
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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. |
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Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
- Install the differential into the right side of the center housing.
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| Illustration 31 | g01029529 |
- Apply Tooling (L) to the mating surfaces of the center housing and the right brake cylinder (4). Align the location marks that were made during the removal procedure. Position brake cylinder (4) onto the center housing and install bolts (9). Tighten bolts (9) to a torque of 79 N·m (58 lb ft). Use Tooling (A) and install spanner nut (12) .
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| Illustration 32 | g01029530 |
- Oscillate the pinion shaft and use Tooling (A) to advance the spanner nuts until there is slight backlash with no end play.
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| Illustration 33 | g01029534 |
- Install a dial type torque wrench onto the pinion shaft. Measure the total rotating torque. Use the following formula in order to calculate the total rotating torque (TRT): P equals the rotating torque that was measured in Step 14. TRT = P + 0.331 N·m (2.93 lb in) to P + 0.556 N·m (4.92 lb in)
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| Illustration 34 | g01038165 |
- 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. Be sure to always maintain slight backlash.
- Mount Tooling (M) onto the center housing, as shown. Measure the backlash between the pinion and the bevel gear. The proper backlash setting is 0.180 to 0.230 mm (0.0071 to 0.0091 inch).
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| Illustration 35 | g01047722 |
- If the backlash is not within the specification, retract one spanner nut and advance the opposite spanner nut equally. This 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 36 | g01029595 |
- Install retainer (10) and bolt (11) into both brake cylinders (4). Tighten bolts (11) to a torque of 13 N·m (10 lb ft).
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| Illustration 37 | g01029578 |
- Install coupling (3), brake discs (2), and plates (1) .
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| Illustration 38 | g01080798 |
End By: Install the axle housing. Refer to Disassembly and Assembly, "Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Install".
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