Salvage of Differential Housing Assembly Used on Off-Highway Trucks {3258, 3283, 3284} Caterpillar

Articulated Truck

725 (S/N: AFX1-UP)

Engine

3516B (S/N: 9AN1-UP)

Excavator

307B (S/N: AFB1-UP)

365C (S/N: ELC1-UP)

374D (S/N: PAS1-UP)

Off-Highway Truck/Tractor

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP; 1GW1-UP)

768B (S/N: 79S1-UP)

768C (S/N: 02X1-UP)

769 (S/N: 99F1-UP)

769B (S/N: 99F1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)

770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-UP)

772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)

772B (S/N: 64W1-UP)

772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; LTS1-UP; KEX1-UP; LTX1-UP)

773 (S/N: 63G1-UP)

773B (S/N: 5SC1-UP; 63W1-UP)

773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)

773F (S/N: EED1-UP; EXD1-UP)

776 (S/N: 14H1-UP; 14W1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP; 3NF1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

777E (S/N: KDP1-UP; KDZ1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

785G (S/N: SH21-UP; RTL1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP; 4AR1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

OEM POWERTRAIN (S/N: DTE1-UP)

Quarry Truck

771C (S/N: 3BJ1-UP)

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

775F (S/N: EYG1-UP; DLS1-UP)

775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Soil Compactor

835 (S/N: 44N1-UP)

Track-Type Loader

933 (S/N: 11A1-UP)

973 (S/N: 11B1-UP)

Track-Type Tractor

D8R (S/N: RJM1-UP)

Transmission

TH55 - KRESS (S/N: KCH1-UP)

Vibratory Soil Compactor

CS433E (S/N: AST1-UP)

Wheel Dozer

834 (S/N: 43E1-UP)

Wheel Loader

992 (S/N: 25K1-UP)

992B (S/N: 25K1-UP)

Wheel Tractor-Scraper

630A (S/N: 52F1-UP)

631A (S/N: 51F1-UP)

631B (S/N: 28F1-UP; 11G1-UP; 13G1-UP)

631C (S/N: 28F1-UP; 67M1-UP)

631D (S/N: 24W1-UP)

631E (S/N: 1AB1-UP; 1BB1-UP)

631E Series II (S/N: 1AB1-UP; 1BB1-UP; 1NB1-UP; 3ND1-UP)

631G (S/N: DFA1-UP; DXE1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; M1W1-UP)

631K (S/N: WT41-UP; WT61-UP; WTR1-UP; WTW1-UP)

633 (S/N: 86H1-UP; 44J1-UP)

633B (S/N: 86H1-UP)

633C (S/N: 66M1-UP)

633D (S/N: 25W1-UP)

633E Series II (S/N: 2PS1-UP)

637 (S/N: 64M1-UP; 65M1-UP; 91N1-UP; 92N1-UP; 79P1-UP)

637D (S/N: 26W1-UP; 27W1-UP)

637E (S/N: 1FB1-UP; 1HB1-UP; 1JB1-UP; 1LB1-UP)

637E Series II (S/N: 1FB1-UP; 1HB1-UP)

637G (S/N: CEH1-UP; CEJ1-UP; DFJ1-UP; AXT1-UP; DEX1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP; WTY1-UP)

639D (S/N: 99X1-UP)

641 (S/N: 64F1-UP; 41M1-UP)

641B (S/N: 65K1-UP)

650 (S/N: 63F1-UP)

650B (S/N: 58K1-UP)

651 (S/N: 33G1-UP; 44M1-UP; WSR1-UP)

651B (S/N: 67K1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 89Z1-UP)

657 (S/N: 31G1-UP; WSJ1-UP; 53K1-UP; WSM1-UP; 46M1-UP)

657B (S/N: 53K1-UP; 68K1-UP; 47M1-UP)

657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; DXG1-UP; GER1-UP; GRS1-UP)

660 (S/N: 90F1-UP)

660B (S/N: 58K1-UP)

666 (S/N: 32G1-UP; 64H1-UP)

666B (S/N: 66K1-UP)

Introduction

Table 1

Revision	Summary of Changes in SEBF8227
14	The information contained in SEBF2177"Thermal Spray Procedures for OHT Differential Housing - Housing and Side Thrust" has been moved and combined with , SEBF8277. Revised effectivity, updated boilerplate, revised Tooling Table3, and reformatted tables.
13	Added new serial number prefixes for New Product Introduction (NPI). Updated copyright date to 2018. Removed old Repair Process Engineering point of contacts. Added new Repair Process Engineering point of contact.
12	Changed part number.
11	Changed procedure to repair bearing journals.
10	Changed all imperial dimensions to reflect three decimal spaces.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

Differential housing assemblies on Off-Highway Trucks can be salvaged by thermal spraying spider shaft bores, bearing journals, axle bores, bearing shoulders, ring gear mounting faces, and split faces. Bolt hole damage and distortion in the flange half can be repaired by sleeving the bolt holes. The repair procedure in this guideline provides a method to salvage differential housings.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse.

Illustration 3	g03704106
Differential Carrier Assembly

Several conditions can cause damage. For example, the differential housing bores can be damaged by foreign material or component failure. Damage to the differential housing can occur from bearing or gear failures. These failures can cause the bores of the housing to become elongated. Damage to the differential housing can also occur when subjected to extreme axial loads.

This guideline identifies the various areas that can be salvaged using the thermal spray. The thermal spray operation must be followed by precision machining and using dimensions provided in this guideline.

Differential housings that meet these salvage guidelines and specifications can be expected to perform normally in the same application.

References

Table 2

References
Media Number	Publication Type & Title
Channel1	"Why Reuse and Salvage Parts"
	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
PERJ1017	Special Publication "Dealer Service Tools Catalog"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF9236	Reuse and Salvage Guidelines "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning Components" (1)
SEBF9238	Reuse and Salvage Guidelines "Fundamentals of Arc Spray for reconditioning Components" (1)
SEBF9240	Reuse and Salvage Guidelines "Fundamentals of Flame Spray for Reconditioning Components" (1)

(1)	Only Cat dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment and always use the correct equipment for all processes in each Thermal Spray Application.

Service Advisories, Service Letters, and Technical Service Bulletins

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NOTICE
The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

Tooling and Equipment

The recommended machines and tooling are listed in Table 3. The salvage procedure can also be completed using equivalent machinery.

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components.

To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Required Tooling and Equipment
Part Number	Description	Designation
— (1)	Personal Protective Equipment (PPE)	Personal Protection
385-9422	Tools (Micrometer) Internal (2 - 24 inch)	Internal Measurement Checks
474-3709 or 474-3710	Instrument Group Micrometer, Inside (8.00 - 32.00 inch)	Internal Measurement Checks
	Instrument Group Micrometer, Inside 200 - 800 mm
473-8688 or 473-8689	Instrument Group Micrometer, Inside 2.00 - 12.00 inch	Internal Measurement Checks
	Instrument Group Micrometer, Inside 50 - 300 mm
6V-7898	Dial Bore Gauge Group	Internal Measurement Checks
6V-6042	Indicator Point Group	Internal Measurement Checks
431-4150	Micrometers External 0 - 25 mm (0 - 1 inch)	External Measurement Checks
473-8690	Instrument Group Micrometer, Outside 0.00 - 4.00 inch	External Measurement Checks
473-8691	Instrument Group Micrometer, Outside 2.00 - 6.00 inch	External Measurement Checks
473-8692	Instrument Group Micrometer, Outside - Digital 152.4 - 304.8 mm (6.00 - 12.00 inch)	External Measurement Checks
367-9109	Digital Caliper 0-150.0 mm (0-6.00 inch)	Profile Measurement
1U-5516	Disc (Coarse)	Surface Preparation / De-burring
4C-6188	Collet (thermal spray 453 powder)	Surface Preparation
1U-5518	Threaded Shaft	Surface Preparation / De-burring
1U-5519	Holder (Disc Pad)	Surface Preparation / De-burring
4C-8514	Wheel (2 x 1 inch) (60 Grit)	Surface Preparation / De-burring
4C-8515	Grinding Wheel (F-Grade) (2 x 1 inch) (120 Grit)	Surface Preparation / De-burring
222-3076	Die Grinder (Right Angle)	Surface Preparation / De-burring
254-5319	Brush 76.2 x 50.8 mm (3.00 x 2.00 inch)	Surface Preparation / De-burring
9U-7377 (2)	Metal Marking Pen	Parts Marking
1U-9918	Brush	General Cleaning
1U-5512	Abrasive Material (Roll)	General Cleaning
8T-7765	Surface Reconditioning Pad (180 Grit)	General Cleaning
162-5791	Towel	General Cleaning
7M-7456	Bearing Mount Compound (50-ML Tube)	Bearing Fitting
8T-5096	Tool Group Dial Indicator	Run-Out Checks
9S-8903	Indicator Contact Point	Run-Out Checks
1U-5518	Threaded Shaft	Run-Out Checks
5P-7414	Seal Pick Kit	Gear/ Shaft Step Inspection
1U-9978	Brush	Paste Application
—	Loctite 680	Bore Sleeving
477-3166 (3)	Tool Group Portable Boring Bar (110 v)	Line Boring
477-3167	Tool Group Portable Boring Bar (240 v)	Line Boring
477-3189	Tool Bore Welding System	Bore Welding
—	Lathe 45.0 mm (1.77 inch)swing	Bore Welding
9U-7231	Flashing Lights Conversion Kit	Visual Surface Inspection (VT)
4C-9442	Light	Visual Surface Inspection (VT)
—	Bright Incandescent Light	Visual Surface Inspection (VT)
263-7184	Crack Detection Kit	Visual Surface Inspection (VT)
459-0184	UV Lamp Kit	Visual Surface Inspection (VT)
288-4209	Paper Towel	Liquid Penetrant Testing (PT)
288-4209	Paper Towel	Liquid Penetrant Testing (PT)
—	Developer	Liquid Penetrant Testing (PT)
—	Penetrating Oil	Liquid Penetrant Testing (PT)
1U-9915	Brush Curved Handle Wire	General Cleaning/ Liquid Penetrant Testing (PT)
—	Solvent Cleaner	General Cleaning/ Liquid Penetrant Testing (PT)
263-7184	Crack Detection Kit (Magnetic Particle)	Dry Magnetic Particle Testing (MPT)
—	Paint Pen	Dry Magnetic Particle Testing (MPT)
459-0184	Lamp Group Ultraviolet	Wet Magnetic Particle Testing (MPT)
505-8671	Fluid Ultrasonic Wear Indicator	Ultrasonic Testing (UT)
415-4055	Tool Group(Ultrasonic)	Ultrasonic Testing (UT)

(1)	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2)	Available in the United States only.
(3)	Various bar lengths and extra Tooling are available through Dealer Service Tools.

Preparation Recommendations

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Note: Clean exterior of the differential housing assembly prior to disassembly to minimize cross-contamination.

• Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect.

• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.

• During cleaning, do not damage machined surfaces.

• Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of internal components.

• Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the parts in a clean container.

• Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust, nicks, and dents.

• Use appropriate thread taps to chase all threaded holes.

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part.

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NOTICE
Do not use numbering stamp punches to mark internal components. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure.

Illustration 4	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

Illustration 5	g03856853
Typical Example

Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 6	g03856857
Typical Example

Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 6. In this example, the gear has a total of 22,000 hours.

Visual Inspection

Visually determine if the differential housing can be salvaged. Damage to machined bolt holes in the flange area may be repaired by enlarging the hole and installing a sleeve.

Illustration 7	g03704110
Inspect all areas indicated by arrows for wear, dents, nicks, and other types of damage.

1. Check bolt hole depth using the bolt without the washer. The bolt must go completely through both parts with sufficient clearance for locknut, washer, and nut.

2. Check the housing for cracks. If the housing is cracked, DO NOT USE AGAIN.

3. Check housing for heat damage and distortion.

4. Check bore and outside diameter bearing surfaces for wear. If worn beyond recommended specification, repair the damage before using again.

Mounting Faces

Illustration 8	g03704114
The damage from fretting on the mounting surface is not excessive. The damage from fretting on the mounting surface must not be more than the amount of damage that is shown here. OK TO USE THIS PART AGAIN

Movement between the halves of the differential housing and between the ring gear and the housing causes the pieces to fret. Fretting refers to the wearing and transferring of metal between the pieces. Any parts that show fretting up to the amount in Illustration 8 can be reused after all high spots are removed. Face off the surface and build up the surface by thermal spray if the damage is deeper. Contact dealer support for dimensions for given parts.

Bore of the Spider Shaft

Illustration 9	g03704115
Typical example of acceptable fretting. OK TO USE THIS PART AGAIN

Some fretting is permitted of the split bore. The bores which are machined in the mounting face of the differential housing may show fretting or wear beyond Illustration 9. The bores may then be built up using thermal spray and machined to original specifications. To perform this procedure the split bore must be assembled and torqued. Contact the Dealer Solution Network (DSN) to obtain dimensional information for given housings.

Side Gear Thrust Faces

Illustration 10	g03704116
The thrust face does not have more than 0.5 mm (0.01968 inch) wear. OK TO USE THIS PART AGAIN

The component is acceptable to be reused if the thrust face does not have more than 0.5 mm (0.01968 inch) of wear.

If the thrust bearing has worn into the housing more than 0.5 mm (0.01968 inch), then DO NOT USE HOUSING AGAIN. No welding on the ductile iron differential half and surfaces that are worn beyond the maximum tolerance may be repaired with thermal spray only. Refer to Illustration 10.

Locating Dowel for the Thrust Bearing

Illustration 11	g03704120
Typical example a loose locating dowel of the differential housing.

If the locating dowel is loose, DO NOT USE HOUSING AGAIN. Loose dowels will break during operation, which will permit the thrust bearing to turn. Housings with worn dowel holes can be salvaged by drilling a new hole in the other half of the housing or by boring the worn hole, plugging the hole with a steel rod, and drilling a new hole in the original location. Refer to Illustration 11.

After relocating or repair of the locating dowel hole, then OK TO USE HOUSING AGAIN.

Support Bearing Journals

Illustration 12	g03704123
Excessive wear on the support bearing journal of the differential housing. OK TO USE HOUSING AGAIN

The support bearing journal of the differential housing must be repaired.

Illustration 13	g03704126
Typical group for the differential housing. (3) Ring Gear Flange (4) Support Bearing Journal (Plain Half) (5) Support Bearing Journal (Flange Half)

The wear tolerances permitted of the outside diameter of the support bearing journals of the differential housing is contained in Tables 4 through 23. Support bearing journals that are worn beyond this amount can be salvaged with thermal spray. Bearings that will be used on support bearing journals that are smaller than the new diameter must be installed using bearing mount compound. Wear on the thrust face up to 0.25 mm (0.00984 inch) can be machined. Thrust surfaces that are worn beyond 0.25 mm (0.00984 inch) can be built up with thermal spray and can be machined to the original dimensions that are provided in the charts.

Specifications for Differential Housing

Illustration 14	g03704130
Differential Housing (Flange Half) Refer to Tables 4 through 6 for dimensions and tolerances.

Table 4

Dimensions and Tolerances of Differential Housing (Flange Half)
Part Number	Spider Shaft Bore Diameter (A)	Housing Diameter (B)	Housing Length (C)	Support Bearing Journal Width (D)	Support Bearing Journal Diameter (E)
4D-5612	Ø 38.023 ± 0.05080 mm (1.497 ± 0.002 inch)	Ø 323.85 ± 0.5 mm (12.74997 ± 0.01968 inch)	198.120 ± 0.5 mm (7.79998 ± 0.01968 inch)	49.276 ± 0.05 mm (1.94000 ± 0.00197 inch)	Ø 114.376 ± 0.021 mm (4.50298 ± 0.00083 inch)
5T-5819	41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	258.5 ± 0.5 mm (10.17715 ± 0.01968 inch)	75.00 ± 0.25 mm (2.95275 ± 0.00984 inch)	Ø 152.588 ± 0.02 mm (6.00739 ± 0.00079 inch)
6G-7532	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	239.00 ± 0.5 mm (9.40943 ± 0.01968 inch)	47.71 ± 0.05 mm (1.87834 ± 0.00197 inch)	Ø 139.837 ± 0.02 mm (5.50538 ± 0.00079 inch)
7I-5877 7I-5881 8W-9448 8X-0315	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	258.5 ± 0.5 mm (10.17715 ± 0.01968 inch)	82.94 ± 0.25 mm (3.26535 ± 0.00984 inch)	Ø 174.81 ± 0.02 mm (6.88227 ± 0.00079 inch)
8D-3477 8W-6569	Ø 38.023 ± 0.05080 mm (1.497 ± 0.002 inch)	Ø 323.85 ± 0.5 mm (12.74997 ± 0.01968 inch)	198.120 ± 0.5 mm (7.79998 ± 0.01968 inch)	49.276 ± 0.05 mm (1.94000 ± 0.00197 inch)	Ø 114.376 ± 0.021 mm (4.50298 ± 0.00083 inch)
8X-7788	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	239.00 ± 0.5 mm (9.40943 ± 0.01968 inch)	47.71 ± 0.05 mm (1.87834 ± 0.00197 inch)	Ø 139.837 ± 0.02 mm (5.50538 ± 0.00079 inch)
8W-9539 123-8503	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	258.5 ± 0.5 mm (10.17715 ± 0.01968 inch)	75.00 ± 0.25 mm (2.95275 ± 0.00984 inch)	Ø 152.512 ± 0.02 mm (6.00440 ± 0.00079 inch)
101-7517	Ø 38.023 ± 0.05080 mm (1.497 ± 0.002 inch)	Ø 323.85 ± 0.5 mm (12.74997 ± 0.01968 inch)	198.120 ± 0.5 mm (7.79998 ± 0.01968 inch)	49.276 ± 0.05 mm (1.94000 ± 0.00197 inch)	Ø 114.437 ± 0.021 mm (4.50538 ± 0.00083 inch)
203-2291 232-1691	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	333.8 ± 0.5 mm (13.14171 ± 0.01968 inch)	157.9 ± 0.5 mm (6.21652 ± 0.01968 inch)	Ø 174.7 ± 0.02 mm (6.87794 ± 0.00079 inch)
275-7897	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	333.8 ± 0.5 mm (13.14171 ± 0.01968 inch)	157.9 ± 0.5 mm (6.21652 ± 0.01968 inch)	Ø 174.7 ± 0.02 mm (6.87794 ± 0.00079 inch)
308-3247	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	251.00 ± 0.5 mm (9.88187 ± 0.01968 inch)	47.71 ± 0.05 mm (1.87834 ± 0.00197 inch)	Ø 139.857 ± 0.02 mm (5.50617 ± 0.00079 inch)
344-6003	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	239.00 ± 0.5 mm (9.40943 ± 0.01968 inch)	47.71 ± 0.05 mm (1.87834 ± 0.00197 inch)	Ø 139.857 ± 0.02 mm (5.50617 ± 0.00079 inch)
368-9128	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	380.00 ± 0.5 mm (14.96060 ± 0.01968 inch)	333.8 ± 0.5 mm (13.14171 ± 0.01968 inch)	157.9 ± 0.5 mm (6.21652 ± 0.01968 inch)	Ø 174.7 ± 0.02 mm (6.87794 ± 0.00079 inch)

Table 5

Dimensions and Tolerances of Differential Housing (Flange Half) continued
Part Number	Differential Ring Gear Mounting (F)	Thrust Face Tolerance (G)	Axle Bore Diameter (K)	Thrust Face Diameter (Q)	Parallel Clearance (P)
4D-5612	485.14 ± 0.5 mm (19.09996 ± 0.01968 inch)	115.57 ± 0.05 mm (4.54999 ± 0.00197 inch)	Ø 82.55 ± 0.25 mm (3.24999 ± 0.00984 inch)	Ø 203.20 ± 0.25 mm (7.99998 ± 0.00984 inch)	83.82 ± 0.05 mm (3.29999 ± 0.00197 inch)
5T-5819	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	125.70 mm (4.94881 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)
6G-7532 8X-7788	506.5 ± 0.5 mm (19.94090 ± 0.01968 inch)	117.25 ± 0.08 mm (4.61613 ± 0.00315 inch)	Ø 87.5 ± 0.5 mm (3.44488 ± 0.01968 inch)	Ø 226.06 ± 0.25 mm (8.89998 ± 0.00984 inch)	101.5 ± 0.3 mm (3.99606 ± 0.01181 inch)
7I-5877 7I-5881 8W-9448 8X-0315	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	125.70 mm (4.94881 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)
8D-3477 8W-6569 101-7517	485.14 ± 0.5 mm (19.09996 ± 0.01968 inch)	115.57 ± 0.05 mm (4.54999 ± 0.00197 inch)	Ø 82.55 ± 0.25 mm (3.24999 ± 0.00984 inch)	Ø 203.20 ± 0.25 mm (7.99998 ± 0.00984 inch)	83.82 ± 0.05 mm (3.29999 ± 0.00197 inch)
8W-9539 123-8503	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	125.70 mm (4.94881 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)
203-2291	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	125.70 mm (4.94881 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)
232-1691, 275-7897	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	127.00 mm (4.99999 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)
308-3247	506.5 ± 0.5 mm (19.94090 ± 0.01968 inch)	117.25 ± 0.08 mm (4.61613 ± 0.00315 inch)	Ø 87.5 ± 0.5 mm (3.44488 ± 0.01968 inch)	Ø 226.06 ± 0.25 mm (8.89998 ± 0.00984 inch)	117.4 ± 0.3 mm (4.62204 ± 0.01181 inch)
344-6003	506.5 ± 0.5 mm (19.94090 ± 0.01968 inch)	117.25 ± 0.08 mm (4.61613 ± 0.00315 inch)	Ø 87.5 ± 0.5 mm (3.44488 ± 0.01968 inch)	Ø 226.06 ± 0.25 mm (8.89998 ± 0.00984 inch)	101.5 ± 0.3 mm (3.99606 ± 0.01181 inch)
368-9128	447.50 ± 0.02 mm (17.61808 ± 0.00079 inch)	127.00 mm (4.99999 inch)	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	102.5 mm (4.03542 inch)

Table 6

Dimensions and Tolerances of Differential Housing (Flange Half) continued
Part Number	Thrust Face Bore Diameter (M)	Radius (H)	Radius (J)	Angle (L)	Chamfer (N)
4D-5612	Ø 114.30 ± 0.05 mm (4.49999 ± 0.00197 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	2.38760 mm (0.094 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
5T-5819	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
6G-7532 8X-7788	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	5.0 mm (0.19685 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
7I-5877 7I-5881 8W-9448 8X-0315	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
8D-3477 8W-6569 101-7517	Ø 114.30 ± 0.05 mm (4.49999 ± 0.00197 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	2.5 ± 0.25 mm (0.09843 ± 0.00984 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
8W-9539 123-8503	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
203-2291 232-1691	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
275-7897	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
308-3247	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	5.0 mm (0.19685 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
344-6003	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	5.0 mm (0.19685 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
368-9128	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)	6.0 ± 0.5 mm (0.23622 ± 0.01968 inch)	3.0 ± 0.5 mm (0.11811 ± 0.01968 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°

Illustration 15	g03704146
Differential housing (Plain Half). Refer to Tables 7 through 9 for dimensions and tolerances.

Table 7

Dimensions and Tolerances of Differential Housing (Plain Half)
Part Number	Spider Shaft Bore Diameter (A)	Housing Diameter (B)	Housing Length (C)	Support Bearing Journal Diameter (D)	Support Bearing Journal Width (E)
4D-5611 6D-7468	Ø 38.02380 ± 0.05080 mm (1.497 ± 0.002 inch)	Ø 323.85000 mm (12.750 inch)	202.69200 mm (7.980 inch)	Ø 133.42620 ± 0.02032 mm (5.2530 ± 0.0008 inch)	41.14800 ± 0.12700 mm (1.62 ± 0.005 inch)
5T-5820	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	230.00 ± 0.5 mm (9.05510 ± 0.01968 inch)	152.512 ± 0.02 mm (6.00440 ± 0.00079 inch)	46.5 ± 0.25 mm (1.83070 ± 0.00984 inch)
6D-8531	Ø 41.19880 ± 0.05080 mm (1.622 ± 0.002 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	225.55200 mm (8.88 inch)	Ø 133.42620 ± 0.02032 mm (5.2530 ± 0.0008 inch)	41.14800 ± 0.12700 mm (1.62 ± 0.005 inch)
6G-7167	Ø 41.19880 ± 0.05080 mm (1.622 ± 0.002 inch)	Ø 352.42 ± 0.25 mm (13.87478 ± 0.00984 inch)	225.50 ± 0.5 mm (8.87794 ± 0.01968 inch)	Ø 133.507 ± 0.02 mm (5.25617 ± 0.00079 inch)	41.35 ± 0.5 mm (1.62795 ± 0.01968 inch)
7I-5879 8W-9546 117-2994	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	230.00 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 152.588 ± 0.02 mm (6.00739 ± 0.00079 inch)	46.5 ± 0.25 mm (1.83070 ± 0.00984 inch)
8D-7827	Ø 38.02380 ± 0.05080 mm (1.497 ± 0.002 inch)	Ø 323.85000 mm (12.750 inch)	202.69200 mm (7.980 inch)	Ø 133.42620 ± 0.02032 mm (5.2530 ± 0.0008 inch)	41.14800 ± 0.12700 mm (1.62 ± 0.005 inch)
8W-6992	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	230.00 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 152.512 ± 0.02 mm (6.00440 ± 0.00079 inch)	46.5 ± 0.25 mm (1.83070 ± 0.00984 inch)
130-6443	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	230.00 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 152.588 ± 0.02 mm (6.00739 ± 0.00079 inch)	48.00 mm (1.88976 inch)
275-7898	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	231.5 mm (9.11416 inch)	Ø 150.056 ± 0.013 mm (5.90770 ± 0.00051 inch)	56.0 mm (2.20472 inch)
232-1690	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	231.5 mm (9.11416 inch)	Ø 150.056 ± 0.013 mm (5.90770 ± 0.00051 inch)	56.0 mm (2.20472 inch)
368-9128	Ø 41.20 ± 0.05 mm (1.62204 ± 0.00197 inch)	Ø 380.00 ± 0.3 mm (14.96060 ± 0.01181 inch)	231.5 mm (9.11416 inch)	Ø 150.056 ± 0.013 mm (5.90770 ± 0.00051 inch)	56.0 mm (2.20472 inch)

Table 8

Dimensions and Tolerances of Differential Housing (Plain Half) continued
Part Number	Axle Bore (K)	Thrust Face Tolerance (G)	Thrust Face Diameter (Q)	Thrust Face Bore Diameter (M)
4D-5611 6D-7468	Ø 106.32440 ± 0.02540 mm (4.186 ± 0.001 inch)	115.57000 ± 0.07620 mm (4.550 ± 0.003 inch)	Ø 206.24800 mm (8.12 inch)	Ø 114.30 ± 0.05 mm (4.50 ± 0.002 inch)
5T-5820	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	125.70 ± 0.08 mm (4.94881 ± 0.00315 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)
6D-8531	Ø 106.32440 ± 0.02540 mm (4.186 ± 0.001 inch)	117.24640 ± 0.07620 mm (4.616 ± 0.003 inch)	Ø 226.06 ± 0.25 mm (8.89998 ± 0.00984 inch)	Ø 120.65 ± 0.5 mm (4.74999 ± 0.01968 inch)
6G-7167	Ø 98.5 mm (3.87795 inch)	117.24640 ± 0.07620 mm (4.616 ± 0.003 inch)	Ø 226.06 ± 0.25 mm (8.89998 ± 0.00984 inch)	Ø 120.65 ± 0.5 mm (4.74999 ± 0.01968 inch)
7I-5879 8W-9546 117-2994 130-6443	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	125.70 ± 0.08 mm (4.94881 ± 0.00315 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)
8D-7827	Ø 106.32440 ± 0.02540 mm (4.186 ± 0.001 inch)	115.57000 ± 0.07620 mm (4.550 ± 0.003 inch)	Ø 206.24800 mm (8.12 inch)	Ø 114.30 ± 0.05 mm (4.50 ± 0.002 inch)
8W-6992	Ø 100.0 ± 0.5 mm (3.93700 ± 0.01968 inch)	125.70 ± 0.08 mm (4.94881 ± 0.00315 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)
232-1690	Ø 98.75 ± 0.25 mm (3.88779 ± 0.00984 inch)	127.00 mm (4.99999 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)
275-7898	Ø 98.75 ± 0.25 mm (3.88779 ± 0.00984 inch)	127.00 mm (4.99999 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)
368-9128	Ø 98.75 ± 0.25 mm (3.88779 ± 0.00984 inch)	127.00 mm (4.99999 inch)	Ø 230.0 ± 0.5 mm (9.05510 ± 0.01968 inch)	Ø 120.5 ± 0.5 mm (4.74408 ± 0.01968 inch)

Table 9

Dimensions and Tolerances of Differential Housing (Plain Half) continued
Part Number	Radius (J)	Angle (L)	Chamfer (N)
4D-5611 6D-7468	2.39 mm (0.094 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
5T-5820	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
6D-8531	2.39 mm (0.094 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
6G-7167	2.5 ± 0.5 mm (0.09843 ± 0.01968 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
7I-5879 8W-9546	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
8D-7827	2.39 mm (0.094 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
8W-6992	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	30°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
117-2994	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
130-6443	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	N/A	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
232-1690	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
275-7898	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°
320-3316	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	45°	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°

Illustration 16	g03704150
183-4745 and 273-0355 Differential Housing (Short Half) Refer to Tables 10 through 12 for dimensions and tolerances.

Table 10

Dimensions and Tolerances of 183-4745 and 273-0355 Differential Housing (Short Half)
Part Number	Spider Shaft Bore Diameter (A)	Housing Diameter (B)	Housing Length (C)	Support Bearing Journal Width (D)	Support Bearing Diameter (E)
183-4745 273-0355	Ø 53.00 ± 0.05 mm (2.08661 ± 0.00197 inch) (4 holes)	Ø 505.00 ± 0.2 mm (19.88185 ± 0.00787 inch)	217.93 mm (8.57990 inch)	Ø 120.29 mm (4.73582 inch)	Ø 489.468 ± 0.025 mm (19.27036 ± 0.00098 inch)

Table 11

Dimensions and Tolerances of 183-4745 and 273-0355 Differential Housing (Short Half) continued
Part Number	Differential Ring Gear Mounting (F)	Thrust Face Tolerance (G)	Radius (H)	Radius (J)	Axle Bore Diameter (K)
183-4745 273-0355	605.00 ± 0.2 mm (23.81885 ± 0.00787 inch)	168.93 mm (6.65077 inch)	5.0 ± 0.5 mm (0.19685 ± 0.01968 inch)	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	Ø 150.0 ± 0.5 mm (5.90550 ± 0.01968 inch)

Table 12

Dimensions and Tolerances of 183-4745 and 273-0355 Differential Housing (Short Half) continued
Part Number	Thrust Face Diameter (M)	Parallel Clearance (P)
183-4745 273-0355	Ø 280.0 ± 0.5 mm (11.02360 ± 0.01968 inch)	53.64 mm (2.11181 inch)
Location	Hole Dimensions and Tolerances
1	Ø 9.0 mm (0.35433 inch) 38.5 ± 0.5 mm (1.51575 ± 0.01968 inch) deep (4 holes)
2	Ø 9.0 mm (0.35433 inch) 15.0 mm (0.59055 inch) deep (3 holes)
3	Ø 12.0 mm (0.47244 inch) (12 holes)

Illustration 17	g03704153
287-7349 Differential Housing (Gear Hub) Refer to Tables 13 through 15 for dimensions and tolerances.

Table 13

Dimensions and Tolerances of 287-7349 Differential Housing (Gear Hub)
Part Number	Spider Shaft Bore Diameter (A)	Support Bearing Journal Diameter (B)	Housing Length (C)	Support Bearing Journal Width (D)	Differential Ring Gear Mounting (F)
287-7349	Ø 42.247 ± 0.013 mm (1.66326 ± 0.00051 inch) (4 holes)	Ø 489.468 ± 0.025 mm (19.27036 ± 0.00098 inch)	165.0 mm (6.49605 inch)	89.36 mm (3.51810 inch)	702.0 mm (27.63774 inch)

Table 14

Dimensions and Tolerances of 287-7349 Differential Housing (Gear Hub) continued
Part Number	Radius (H)	Axle Bore Diameter (K)		Chamfer (N)	Parallel Clearance (P)
287-7349	1.6 mm (0.06299 inch)	Ø 425.2 mm (16.74012 inch)		1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°	80.0 mm (3.14960 inch)

Table 15

Hole Axis Dimensions of 287-7349 Differential Housing (Gear Hub)
Location	X Axis	Y Axis
1	56.0 mm (2.20472 inch)	312.5 mm (12.30313 inch)
2	97.6 mm (3.84251 inch)	302.1 mm (11.89368 inch)
3	137.4 mm (5.40944 inch)	286.2 mm (11.26769 inch)
4	174.8 mm (6.88188 inch)	265.1 mm (10.43699 inch)
5	208.9 mm (8.22439 inch)	239.1 mm (9.41337 inch)
6	239.3 mm (9.42124 inch)	208.7 mm (8.21652 inch)
7	265.2 mm (10.44 inch)	174.5 mm (6.87 inch)
8	286.3 mm (11.27163 inch)	137.2 mm (5.40156 inch)
9	302.2 mm (11.89761 inch)	97.3 mm (3.83070 inch)
10	312.6 mm (12.30706 inch)	55.7 mm (2.19291 inch)
Location	Hole Dimensions and Tolerances
11	Ø 26.0 mm (1.02362 inch) (40 holes)

Illustration 18	g03704165
183-4747 and 273-0356 Differential Housing (Long Half) Refer to Tables 16 through 19 for dimensions and tolerances.

Table 16

Dimensions and Tolerances of 183-4747 and 273-0356 Differential Housing (Long Half)
Part Number	Spider Shaft Bore Diameter (A)	Housing Diameter (B)	Housing Length (C)	Support Bearing Journal Width (D)	Support Bearing Journal Diameter (E)
183-4747 273-0356	Ø 53.00 ± 0.05 mm (2.08661 ± 0.00197 inch) (4 holes)	Ø 479.0 ± 0.2 mm (18.85823 ± 0.00787 inch)	772.52 mm (30.41411 inch)	72.0 mm (2.83464 inch)	Ø 241.450 ± 0.025 mm (9.50589 ± 0.00098 inch)

Table 17

Dimensions and Tolerances of 183-4747 and 273-0356 Differential Housing (Long Half) continued
Part Number	Differential Ring Gear Mounting (F)	Thrust Face Tolerance (G)	Radius (H)	Radius (J)	Axle Bore Diameter (K)
183-4747 273-0356	579.94 ± 0.02 mm (22.83224 ± 0.00079 inch)	168.93 mm (6.65077 inch)	5.0 ± 1 mm (0.19685 ± 0.03937 inch)	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	Ø 200.00 ± 0.05 mm (7.87400 ± 0.00197 inch)

Table 18

Dimensions and Tolerances of 183-4747 and 273-0356 Differential Housing (Long Half) continued
Part Number	Angle (L)	Thrust Face Diameter (M)	Chamfer (N)	Parallel Clearance (P)	Thrust Face Bore Diameter (Q)
183-4747 273-0356	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°	Ø 280.00 ± 0.5 mm (11.02360 ± 0.01968 inch)	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°	40.0 mm (1.57480 inch)	Ø 150.0 ± 0.5 mm (5.90550 ± 0.01968 inch)

Table 19

Hole Axis Dimensions of 183-4747 and 273-0356 Differential Housing (Long Half)
Location	X Axis	Y Axis
1	264.0 mm (10.39368 inch)	0.00 mm (0.00000 inch)
2	259.99 mm (10.23581 inch)	45.84 mm (1.80472 inch)
3	248.08 mm (9.76691 inch)	90.29 mm (3.55472 inch)
4	228.63 mm (9.00116 inch)	132.00 mm (5.19684 inch)
5	202.24 mm (7.96219 inch)	169.70 mm (6.68109 inch)
6	169.70 mm (6.68109 inch)	202.24 mm (7.96219 inch)
7	132.00 mm (5.19684 inch)	228.63 mm (9.00116 inch)
8	90.29 mm (3.55472 inch)	248.08 mm (9.76691 inch)
9	45.84 mm (1.80472 inch)	259.99 mm (10.23581 inch)
10	0.00 mm (0.00000 inch)	264 mm (10.39368 inch)
Location	Hole Dimensions and Tolerances
11	Ø 19.45 mm (0.76575 inch) (36 holes)
12	Ø 21.5 mm (0.84646 inch) 65.0 mm (2.55905 inch) deep (12 holes)
13	Ø 16.0 mm (0.62992 inch)
14	Ø 9.0 mm (0.35433 inch) 15.0 mm (0.59055 inch) deep (3 holes)

Illustration 19	g03704177
279-5122 Differential Housing (Long Half) Refer to Tables 20 through 23 for dimensions and tolerances.

Table 20

Dimensions and Tolerances of 279-5122 Differential Housing (Long Half)
Part Number	Housing Diameter (B)	Housing Length (C)	Support Bearing Length (D)	Support Bearing Diameter (E)	Differential Ring Gear Mounting (F)
279-5122	Ø 439.8 ± 0.1 mm (17.31493 ± 0.00394 inch) (4 holes)	652.5 mm (25.68892 inch)	72.0 mm (2.83464 inch)	Ø 241.45 ± 0.025 mm (9.50589 ± 0.00098 inch)	543.0 ± 0.2 mm (21.37791 ± 0.00787 inch)

Table 21

Dimensions and Tolerances of 279-5122 Differential Housing (Long Half) continued
Part Number	Thrust Face Tolerance (G)	Radius (H)	Radius (J)	Axle Bore Diameter (K)	Angle (L)
279-5122	62.9 mm (2.47637 inch)	.8 ± 0.2 mm (0.03150 ± 0.00787 inch)	1.6 ± 0.4 mm (0.06299 ± 0.01575 inch)	Ø 200.0 ± 0.05 mm (7.87400 ± 0.00197 inch)	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°

Table 22

Dimensions and Tolerances of 279-5122 Differential Housing (Long Half) continued
Part Number	Thrust Face Diameter (M)	Chamfer (N)	Parallel Clearance (P)	Thrust Face Bore Diameter (Q)
279-5122	Ø 280.0 ± 0.5 mm (11.02360 ± 0.01968 inch)	1.5 ± 0.5 mm (0.05906 ± 0.01968 inch) × 45°	44.0 mm (1.73228 inch)	Ø 50.0 ± 0.5 mm (5.90550 ± 0.01968 inch)

Table 23

Hole Axis Dimensions of 279-5122 Differential Housing (Long Half)
Location	X Axis	Y Axis
1	243.7 mm (9.59447 inch)	43.00 mm (1.69291 inch)
2	232.6 mm (9.15746 inch)	84.6 mm (3.33070 inch)
3	214.3 mm (8.43699 inch)	123.8 mm (4.87401 inch)
4	189.6 mm (7.46455 inch)	159.1 mm (6.26377 inch)
5	159.1 mm (6.26377 inch)	189.6 mm (7.46455 inch)
6	123.8 mm (4.87401 inch)	214.3 mm (8.43699 inch)
7	84.6 mm (3.33070 inch)	232.6 mm (9.15746 inch)
8	43.00 mm (1.69291 inch)	243.7 mm (9.59447 inch)
Location	Hole Dimensions and Tolerances
9	Ø 22.0 mm (0.86614 inch) (32 holes)
10	Ø 16.0 mm (0.62992 inch)

Check Differential Housing Dimensions

Clean the differential housing thoroughly, prior to this procedure. Check the roundness of spider shaft bores, bearing thrust face, and support bearing journals.

1. Secure the differential housing into the chuck of the lathe.
   Show/hide table

   Illustration 20	g03704182
   Check the diameter of the flange faces.

   Show/hide table

   Illustration 21	g03704183
   Check outside diameter and internal thrust faces.

2. Position a dial indicator and center (zero) the differential housing to within 0.13 mm (0.005 inch) Total Indicator Reading (TIR).

3. Record the readings for future machining operations.

4. Rework any spider shaft bore, support bearing journal, or thrust face that fail to meet tolerances.

Differential Housing Bolt Hole

The bolt holes in the housing can be damaged or distorted by forces exerted against the differential. Maintaining the proper geometry between these bolt hole locations are important. Bolt holes that become elongated or distorted should be drilled oversize and sleeved.

If cracks originating or entering into any bolt hole are found in the differential housing, then DO NOT USE THE HOUSING AGAIN.

Illustration 22	g03704187
Hole Axis Locations of 8D-3477, 8W-6569, and 101-7517 Differential Housing (Flange Half).

Table 24

Hole Axis Dimensions of 8D-3477, 8D-6569, and 101-7517 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	223.52 mm (8.79998 inch)	0.00 mm (0.0000 inch)
2	220.11 mm (8.66573 inch)	38.81 mm (1.52795 inch)
3	210.03 mm (8.26888 inch)	76.45 mm (3.00984 inch)
4	193.57 mm (7.62085 inch)	111.76 mm (4.39999 inch)
5	171.22 mm (6.74093 inch)	143.68 mm (5.65668 inch)
6	143.68 mm (5.65668 inch)	171.22 mm (6.74093 inch)
7	111.76 mm (4.39999 inch)	193.57 mm (7.62085 inch)
8	76.45 mm (3.00984 inch)	210.03 mm (8.26888 inch)
9	38.81 mm (1.52795 inch)	220.11 mm (8.66573 inch)
10	0.00 mm (0.000 inch)	223.52 mm (8.79998 inch)
11	93.0 mm (3.66141 inch)	0.00 mm (0.000 inch)
Location	Hole Dimensions and Tolerances
12	Ø 20.5 mm (0.80708 inch) (36 holes)
13	Ø 33.3 mm (1.31 inch) 38.0 ± 0.08 mm (1.49606 ± 0.00315 inch) Depth (8 holes)
14	Ø 6.15 ± 0.02 mm (0.24213 ± 0.000079 inch) (2 holes) 13.2 mm (0.51968 inch) Depth (2 holes)

Illustration 23	g03704195
Hole Axis Locations of 8D-3477, 8W-6569, and 101-7517 Differential Housing (Flange Half).

Table 25

Hole Axis Dimensions of 8D-3477, 8W-6569, and 101-7517 Differential Housing (Flange Half)
Location	X-Axis	Y-Axis
1	0.00 mm (0.000 inch)	223.52 mm (8.79998 inch)
2	38.81 mm (1.52795 inch)	220.11 mm (8.66573 inch)
3	76.45 mm (3.00984 inch)	210.03 mm (8.26888 inch)
4	111.76 mm (4.39999 inch)	193.57 mm (7.62085 inch)
5	143.68 mm (5.65668 inch)	171.22 mm (6.74093 inch)
6	171.22 mm (6.74093 inch)	143.68 mm (5.65668 inch)
7	193.57 mm (7.62085 inch)	111.76 mm (4.39999 inch)
8	210.03 mm (8.26888 inch)	76.45 mm (3.00984 inch)
9	220.11 mm (8.66573 inch)	38.81 mm (1.52795 inch)
10	223.52 mm (8.79998 inch)	0.00 mm (0.000 inch)

Illustration 24	g03704203
Hole Axis Locations of 6G-7532, 8X-7788, 308-3247, and 344-6003 Differential Housing (Flange Half).

Table 26

Hole Axis Dimensions of 6G-7532, 8X-7788, 308-3247, and 344-6003 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	66.06 mm (2.60078 inch)	203.05 mm (7.99408 inch)
2	117.55 mm (4.62794 inch)	178.23 mm (7.01692 inch)
3	166.93 mm (6.57203 inch)	133.12 mm (5.24093 inch)
4	199.92 mm (7.87085 inch)	74.93 mm (2.94999 inch)
5	212.65 mm (8.37203 inch)	19.23 mm (0.75709 inch)
6	N/A	0.00 mm (0.000 inch)
7	28.58 mm (1.12519 inch)	109.58 mm (4.31416 inch)
8	92.63 mm (3.64684 inch)	154.25 mm (6.07282 inch)
9	147.62 mm (5.81180 inch)	192.38 mm (7.57400 inch)
10	183.24 mm (7.21416 inch)	211.58 mm (8.32990 inch)
Location	Hole Dimensions and Tolerances
1	17.5 mm (0.68898 inch) (4 holes)
10	18.25 mm (0.71850 inch) (14 holes)
11	20.5 mm (0.80708 inch) 38.1 ± 0.08 mm (1.50000 ± 0.00315 inch) (8 holes)
12	6.15 ± 0.02 mm (0.24213 ± 0.00079 inch) 13.0 mm (0.51181 inch) deep (2 holes)

Illustration 25	g03704208
Hole Axis Locations of 7I-5881 and 8X-0315 Differential Housing (Flange Half).

Table 27

Hole Axis Dimensions of 7I-5881 and 8X-0315 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	0.00 mm (0.000 inch)	213.51 mm (8.40589 inch)
2	44.39 mm (1.74763 inch)	208.84 mm (8.22203 inch)
3	86.84 mm (3.41889 inch)	195.05 mm (7.67912 inch)
4	125.50 mm (4.94094 inch)	172.73 mm (6.80038 inch)
5	158.67 mm (6.24684 inch)	142.87 mm (5.62479 inch)
6	184.91 mm (7.27991 inch)	106.76 mm (4.20314 inch)
7	203.06 mm (7.99447 inch)	65.98 mm (2.59763 inch)
8	212.34 mm (8.35983 inch)	22.32 mm (0.87874 inch)
9	104.17 mm (4.10117 inch)(1)	0.00 mm (0.000 inch)
Location	Hole Dimensions and Tolerances
10	Ø 19.45 ± 0.02 mm (0.76575 ± 0.00079 inch) (30 holes)
11	Ø 21.5 ± 0.02 mm (0.84646 ± 0.00079 inch) 71.0 mm (2.79527 inch) deep M24 ×3 THD 56.0 mm (2.20472 inch) deep (8 holes)
12	Ø 9.34 ± 0.013 mm (0.36772 ± 0.00051 inch) 12.0 ± 0.5 mm (0.47244 ± 0.01968 inch)(2) deep (2 holes)

(1)	For 8X-0315, the dimension is 104.14 mm (4.09999 inch)
(2)	For 8X-0315, the hole size and diameter are Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch)

Illustration 26	g03704218
Hole Axis Locations of 7I-5881 and 8X-0315 Differential Housing (Flange Half).

Table 28

Hole Axis Dimensions of 7I-5881 and 8X-0315 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	0.00 mm (0.000 inch)	213.51 mm (8.40589 inch)
2	44.39 mm (1.74763 inch)	208.84 mm (8.22203 inch)
3	86.84 mm (3.41889 inch)	195.05 mm (7.67912 inch)
4	125.50 mm (4.94094 inch)	172.73 mm (6.80038 inch)
5	158.67 mm (6.24684 inch)	142.87 mm (5.62479 inch)
6	184.91 mm (7.27991 inch)	106.76 mm (4.20314 inch)
7	203.06 mm (7.99447 inch)	65.98 mm (2.59763 inch)
8	212.34 mm (8.35983 inch)	22.32 mm (0.87874 inch)

Illustration 27	g03704223
Hole Axis Locations of 203-2291, 232-1691, 275-7897, and 368-9128 Differential Housing (Flange Half).

Table 29

Hole Axis Dimensions of 203-2291, 232-1691, 275-7897, and 368-9128 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	0.00 mm (0.000 inch)	213.51 mm (8.40589 inch)
2	44.39 mm (1.74763 inch)	208.84 mm (8.22203 inch)
3	86.84 mm (3.41889 inch)	195.05 mm (7.67912 inch)
4	125.50 mm (4.94094 inch)	172.73 mm (6.80038 inch)
5	158.67 mm (6.24684 inch)	142.87 mm (5.62479 inch)
6	184.91 mm (7.27991 inch)	106.76 mm (4.20314 inch)
7	203.06 mm (7.99447 inch)	65.98 mm (2.59763 inch)
8	212.34 mm (8.35983 inch)	22.32 mm (0.87874 inch)
12(1)	98.00 mm (3.85826 inch)	0.00 mm (0.000 inch)
13(2)	104.17 mm (4.10117 inch)	0.00 mm (0.000 inch)
Location	Hole Dimensions and Tolerances
9	Ø 10.5 mm (0.41338 inch) B 40.0 mm (1.57480 inch) deep (12 holes)
10	Ø 19.45 mm (0.76575 inch) A (30 holes)
11	Ø 21.5 mm (0.84646 inch) A 71.0 mm (2.79527 inch) deep (8 holes)
12(1)	Ø 7.00 mm (0.27559 inch) 25.0 mm (0.98425 inch) deep (4 holes)
13(2)	Ø 9.34 ± 0.013 mm (0.36772 ± 0.00051 inch) 12.0 ± 0.5 mm (0.47244 ± 0.01968 inch) deep (2 holes)

(1)	Dimensions for 232-1691
(2)	Dimensions for 203-2291

Illustration 28	g03704227
Hole Axis Locations of 203-2291, 232-1691, 275-7897, and 368-9128 Differential Housing (Flange Half).

Table 30

Hole Axis Dimensions of 203-2291, 232-1691, 275-7897, and 368-9128 Differential Housing (Flange Half)
Location	X Axis	Y Axis
1	0.00 mm (0.000 inch)	213.51 mm (8.40589 inch)
2	44.39 mm (1.74763 inch)	208.84 mm (8.22203 inch)
3	86.84 mm (3.41889 inch)	195.05 mm (7.67912 inch)
4	125.50 mm (4.94094 inch)	172.73 mm (6.80038 inch)
5	158.67 mm (6.24684 inch)	142.87 mm (5.62479 inch)
6	184.91 mm (7.27991 inch)	106.76 mm (4.20314 inch)
7	203.06 mm (7.99447 inch)	65.98 mm (2.59763 inch)
8	212.34 mm (8.35983 inch)	22.32 mm (0.87874 inch)

Illustration 29	g03704265
Hole Axis Locations of 5T-5819, 7I-5877, and 8W-9448 Differential Housing (Flange Half).

Table 31

Hole Axis Dimensions of 5T-5819, 7I-5877and 8W-9448 Differential Housing (Flange Half)
Location	X Axis	Y Axis
13	22.20 mm (0.87401 inch)	212.35 mm (8.36022 inch)
14	76.52 mm (3.01259 inch)	199.33 mm (7.84762 inch)
15	128.49 mm (5.05865 inch)	170.52 mm (6.71337 inch)
16	170.52 mm (6.71337 inch)	128.49 mm (5.05865 inch)
17	199.33 mm (7.84762 inch)	76.52 mm (3.01259 inch)
18	212.35 mm (8.36022 inch)	22.20 mm (0.87401 inch)
19	104.14 mm (4.09999 inch)(1)	0.00 mm (0.000 inch)
Location	Hole Dimensions and Tolerances
20	Ø 18.25 ± 0.05 mm (0.71850 ± 0.00197 inch) (24 holes)
21	Ø 6.165 ± 0.013 mm (0.24272 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep (2 holes)(2)

(1)	For 7I-5877 the dimension is 104.17 mm (4.10117 inch)
(2)	For 7I-5877 the hole size and diameter are Ø 9.340 ± 0.013 mm (0.36772 ± 0.00051 inch) 12.0 ± 0.5 mm (0.47244 ± 0.01968 inch) deep (2 holes)

Illustration 30	g03704268
Hole Axis Locations of 5T-5819, 7I-5877, and 8W-9448 Differential Housing (Flange Half).

Table 32

Hole Axis Dimensions of 5T-5819, 7I-5877, and 8W-9448 Differential Housing (Flange Half)
Location	X Axis	Y Axis
13	22.20 mm (0.87401 inch)	212.39 mm (8.36179 inch)
14	76.52 mm (3.01259 inch)	199.33 mm (7.84762 inch)
15	128.49 mm (5.05865 inch)	170.52 mm (6.71337 inch)
16	170.52 mm (6.71337 inch)	128.49 mm (5.05865 inch)
17	199.33 mm (7.84762 inch)	76.52 mm (3.01259 inch)
18	212.39 mm (8.36179 inch)	22.20 mm (0.87401 inch)

Illustration 31	g03704285
Hole Axis Locations of 8W-9539 and 123-8503 Differential Housing (Flange Half).

Table 33

Hole Axis Dimensions of 8W-9539 and 123-8503 Differential Housing (Flange Half)
Location	X Axis	Y Axis
22	76.52 mm (3.01259 inch)	199.33 mm (7.84762 inch)
23	128.49 mm (5.05865 inch)	170.52 mm (6.71337 inch)
24	170.52 mm (6.71337 inch)	128.49 mm (5.05865 inch)
25	199.33 mm (7.84762 inch)	76.52 mm (3.01259 inch)
26	104.14 mm (4.09999 inch)	0.00 mm (0.000 inch)
Location	Hole Dimensions and Tolerances
27	Ø 9.34 ± 0.013 mm (0.36772 ± 0.00051 inch) 12.0 ± 0.50 mm (0.47244 ± 0.01968 inch) deep (2 holes)
28	Ø 21.5 ± 0.02 mm (0.84646 ± 0.00079 inch) 71.0 mm (2.79527 inch) deep M24 × 3 THD 56.0 mm (2.20472 inch) deep (8 holes)
29	Ø 18.25 ± 0.05 mm (0.71850 ± 0.00197 inch) (16 holes)

Illustration 32	g03704291
Hole Axis Locations of 8W-9539 and 123-8503 Differential Housing (Flange Half).

Table 34

Hole Axis Dimensions of 8W-9539 and 123-8503 Differential Housing (Flange Half)
Location	X Axis	Y Axis
22	76.52 mm (3.01259 inch)	199.33 mm (7.84762 inch)
23	128.49 mm (5.05865 inch)	170.52 mm (6.71337 inch)
24	170.52 mm (6.71337 inch)	128.49 mm (5.05865 inch)
25	199.33 mm (7.84762 inch)	76.52 mm (3.01259 inch)

Illustration 33	g03704297
Hole Locations of Differential Housing (Plain Half)

Table 35

Hole Dimensions and Tolerances of Differential Housing (Plain Half)
Location	4D-5611 6D-7468	5T-5820 8W-6992	6D-8531	6G-7167	8D-7827	8W-9546	8X-0315
30(1)	19.56 mm (0.77008 inch)	Ø 24.0 mm (0.9448 inch) 42.86 ± 0.80 mm (1.68740 ± 0.03150 inch)	Ø 20.5 mm (0.80708 inch)	Ø 20.5 mm (0.80708 inch)	Ø 20.5 mm (0.80708 inch)	Ø 26.00 mm (1.0236 inch) 55.0 ± 1 mm (2.16535 ± 0.03937 inch)	Ø 21.5 mm (0.8464 inch) 71 deep M24 x 3 THD 56 deep
31(2)	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.0 ± 1 mm (0.51181 ± 0.03937 inch) deep

(1)	8 Holes
(2)	2 Holes

Illustration 34	g03704299
Hole Locations of Differential Housing (Plain Half)

Table 36

Hole Dimensions and Tolerances of Differential Housing (Plain Half)
Location	7I-5879 117-2994 130-6443	232-1690	275-7898	368-9128
30(1)	Ø 26.0 mm (1.02362 inch) 55.0 ± 1 mm (2.16535 ± 0.03937 inch)	Ø 26.0 mm (1.02362 inch) 55.0 ± 1 mm (2.16535 ± 0.03937 inch)	Ø 26.0 mm (1.02362 inch) 55.0 ± 1 mm (2.16535 ± 0.03937 inch)	Ø 26.0 mm (1.02362 inch) 55.0 ± 1 mm (2.16535 ± 0.03937 inch)
31(2)	Ø 9.34 ± 0.013 mm (0.36772 ± 0.00051 inch) 12.0 ± 0.5 mm (0.47244 ± 0.01968 inch) deep	Ø 7 mm (0.27559 inch) 11.5 mm (0.45276 inch) deep	N/A	N/A
32	Ø 27.0 mm (1.06299 inch) 12 Holes M8 x 1.25 - 6H THD 19 deep	Ø 7 mm (0.27559 inch) 27.0 mm (1.06299 inch) deep (12 holes)	Ø 7 mm (0.27559 inch) 27.0 mm (1.06299 inch) deep (12 holes)	Ø 7 mm (0.27559 inch) 27.0 mm (1.06299 inch) deep (12 holes)
33	Ø 6.16 ± 0.013 mm (0.24252 ± 0.00051 inch) 13.5 ± 1 mm (0.53150 ± 0.03937 inch) deep	N/A	N/A	N/A

(1)	8 Holes
(2)	2 Holes

Rework Procedures

Support Bearing Journals and Gear Thrust Faces

Show/hide table

Illustration 35	g03704302
Spider gear thrust faces, bores, and carrier faces after thermal spray operation.

1. Thermal spray all surfaces and bores before machining. Refer to Illustration 35.
   Show/hide table

   Illustration 36	g03704304
   Machine bearing thrust face and bore.

2. Machine all thrust faces and bores according to specifications.
   Show/hide table

   Illustration 37	g03704305
   Installation of spider shaft prior to assembly of the differential halves.

3. Install the spider shaft in the flange.
   Show/hide table

   Illustration 38	g03704106
   Assemble the carrier prior to machining the support bearing journals.

4. Assemble the carrier.

   Note: Assemble 8W-6993 differential housing assembly and 5T-5775 differential housing assembly with spider shaft in place. Install and tighten bolts to a torque of 1006 ± 102 N·m (742 ± 75 lb ft).

   Show/hide table

   Illustration 39	g03704310
   Use two dial indicators to align the assembled carrier for final machining of support bearing journals.

5. Secure the carrier assembly into the chuck of a lathe and align for machining.

Reworking Spider Shaft Bores, Pinion Thrust Face, and Split Face

This operation requires a numerically controlled machine or an indexing table. The positioning of the part manually is not recommended.

Show/hide table

Illustration 40	g03704317
Differential housing after thermal spray operation. The differential housing is ready to begin machining.

1. Thermal spray all areas that need to be reworked.
   Show/hide table

   Illustration 41	g03704320
   Secure the differential housing to the machine base using bolt and universal washer.

2. Attach the differential housing to machine base, but do not tighten completely. Both plain and flange differential housing can be located using the keyway and held in place with a stepped universal washer.
   Show/hide table

   Illustration 42	g03704323
   Align and secure the differential housing.

3. Ensure that split face is parallel to machine table and align bores to be machined. Secure the housing to the table.
   Show/hide table

   Illustration 43	g03704324
   Machine pin bore.

   Note: The plain half of the differential housing uses the same locating and machining operation as the flange half of the differential housing. Check parallel dimensions of cross shaft bores, thrust faces, and split faces using the same fixture setup.

   Show/hide table

   Illustration 44	g03704327
   Bolt the parasitic block in place.

4. Center (zero) the boring bar to the split line of the carrier. Bolt a parasitic block in place to determine the relationship of the bore. Due to the thermal spray operation a possible four-cut procedure may be required with two rough bore cuts, a semi-finish, and a finish cut.
   Show/hide table

   Illustration 45	g03704330
   Typical example of a modified spider shaft used to obtain proper dimension for machining shoulder of spider gear thrust face.

5. Machine the thrust face.

Thermal Spray

Thermal spray is an acceptable method of restoring a surface to the original size. Each step in the procedure is critical in achieving the desired coating, bond, and surface texture.

Part Description

Table 37

Base Metal	Ductile Iron
Hardness	217-269 BHN

Arc Spray Equipment and Procedure

Table 38

Maximum Surface Texture	3.5 µm (140.00 µinch)
Reason for Spraying	Wear
Mating Part Contact Area & Material	Housing
Arc Spray Equipment Type	SmartArc byOerlikon Metco,TAFA 8830 MHU, or 8835 MHU
Wire	TAFA 30T Wire Top Coat, TAFA 75B Bond Coat
Finish Thickness	As Required
Spray Angle	90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe
Rotation Speed	92.0 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit blast if necessary
Equipment Required	Vertical Lathe
Recommended Cutting Tool	ISCAR DNMG 432TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)

Table 39

Arc Spray		Procedure		Check List
Clean Part		Degrease in hot caustic solution
Undercut		To "tru-up" surface
Chamfer		If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser
Mask for Grit Blaster		Duct Tape
Grit Blast Equipment		Pressure type only
Grit Type and Size		24 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask		Remove mask material, make sure that surface is clean
Mask for Thermal Spray		Antibond or Blue Layout Dye
Thermal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA 30T	TAFA 30T
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	31V	31V
	Amps	150 Amps	175 Amps
	Gun to Work Distance (Standoff)	166 mm (6.5 inch)	166 mm (6.5 inch)
	Spray Rate/Build Up	0.058 mm (0.0023 inch)/pass	0.058 mm (0.0023 inch)/pass
	Rotation Speed of Part (RPM)	RPM varies depending on diameter
	Rotation Speed of Part	92.0 SMPM (300.00 SFPM)
	Traverse Rate of Gun	11.0 SMPM (40.00 SFPM)
Gun Fixturing Method		Machine mount or hand held
Finishing Equipment		Lathe
Part/Cutter Rotation Roughing		50.0 SMPM (150.00 SFPM)
Part/Cutter Rotation Finishing		75.0 SMPM (250.00 SFPM)
Coolant		Oil base synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max.
Depth of Finish Cut		0.25 mm (0.010 inch) per side max.

Flame Spray Equipment and Procedure

Table 40

Maximum Surface Texture	3.6 µm (140.00 µinch)
Reason for Spraying	Wear
Mating Part Contact Area & Material	Housing
Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453
Finish Thickness	As Required
Finishing Allowance	0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle	90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe
Rotation/Traverse Speed	91.4 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit Blast if necessary
Finishing Method	Machine
Machining Equipment Type	Vertical Lathe
Recommended Cutter Grade	C-2, 883 Carboloy, or equivalent

Table 41

Flame Spray Process (6P)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	To "tru-up" surface
Remove Oxide	Use fiber flap brush or Clean/strip disc
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Blast	Duct Tape
Blast Equipment	Pressure type only
Grit Type and Size	24 mesh Aluminum Oxide
Blast Air Pressure	690 kPa (100.0 psi)
Blast Nozzle to Work Distance	51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Spray	Metco Antibond or Blue Layout Dye
Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	If desired
Nozzle	6P-C7A-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per min
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed Of Part (RPM)	RPM varies depending on diameter
Rotation Speed Of Part	91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun	15.24 SMPM (50.000 SFPM)
Gun Fixturing Method	Machine mount or hand held
Top Coat/Thickness	0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment	Lathe
Part/Cutter Rotation	91.4 SMPM (300.00 SFPM)
Traverse Speed	0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution
Depth of Rough Cut	0.38 to 0.51 mm (0.015 to 0.020 inch) per side
Depth of Finish Cut	0.25 to 0.38 mm (0.010 to 0.015 inch) per side
Additional Finish Method	Emery cloth for desired finish

Crack Detection Methods

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NOTICE
Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

There are four major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing and (PT), Dry / Wet Magnetic Particle Testing (MPT).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, and PT, Dry/ Wet MPT are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 42 for advantages and disadvantages and Table 43 for standards and requirements for these NDT methods.

Table 42

Crack Detection Methods Advantages vs. Disadvantages
Detection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least Expensive - Detects most damaging defects. - Immediate Results - Minimum part preparation	- Limited to surface-only defects. - Requires inspectors to have broad knowledge of welding and fabrication in addition to Non-Destructive Testing (NDT).
Liquid Penetrant Testing (PT)	- Inexpensive - Minimal Training - Portable - Works on nonmagnetic material.	- Least Sensitive - Detects surface cracks only. - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MPT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only. - Less sensitive than Wet Magnetic Particle Testing (MPT).
Wet Magnetic Particle (MPT)	- More sensitive than Liquid Penetrant Testing (PT). - Detects subsurface as much as 0.13 mm (0.005 inch).	- Requires power for light. - Works on magnetic material only. - Liquid composition and agitation must be monitored.

Table 43

Applicable Crack Detection Standards
Detection Method	Standard	Acceptance Criteria	Minimum Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Magnetic Particle Testing (MPT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A

Visual Surface Inspection (VT)

Illustration 46	g06124166
Example of Visual Surface Inspection (VT) Tooling (A) Flashlight (or adequate light source) (B) Magnifying Glass (C) Tape Measure (or other measuring device) (D) Inspection Mirror

Refer to Tooling and Equipment Table 3for part numbers.

Components and welds that are to be tested using PT, or MPT shall first be subject to a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 46. Personnel performing VT shall either be trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. Personnel performing VT shall take routine eye exams.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetration Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 47	g06084048
Typical example of pre-cleaning the testing area.

1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.
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   Illustration 48	g06084053
   Typical example of applying penetrating oil to areas to be tested.

2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrating oil to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.
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   Illustration 49	g06084060
   Typical example of removing penetrating oil with a cloth.

3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 50	g06084070
   Typical example of applying the developer.

4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately 203 - 305 mm (8 - 12 inch) away from part. Apply an even, thin layer of developer over the area being tested. A few thin layers are a better application method than one thick layer.
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   Illustration 51	g03773759
   Typical example of cracks found during Liquid Penetrant Testing (PT).

5. Allow the developer to dry completely for 10 to 15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 51. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MPT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 52	g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MPT). (B) Electromagnetic Yoke (C) Dry Powder Bulb

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MPT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 53	g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MPT). (B) Electromagnetic Yoke (D) Ultraviolet Lamp

Illustration 54	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions, refer to Illustration 54. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 5 mm²/_s (5 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 5 mm²/_s (5 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
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   Illustration 55	g03536210

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 55 for an example of yoke placement.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.