Usage:
Disassemble Front And Rear Differentials (930 Only)
start by:
a) remove front or rear differential
1. Put the differential and carrier assembly on tooling (A) with the bevel gear down as shown.
2. Remove the bolts that hold pinion housing (1) to carrier assembly (2).
3. Install two 3/8"-16 NC forged eyebolts in the top of housing (1) and fasten a hoist to it.
4. Use two 1/2"-13 NC forcing screws to loosen housing (1) from carrier assembly (2). Remove the housing and pinion gear as a unit. The weight of the unit is 80 lb. (36 kg).
5. Remove shims (4) from carrier assembly (2). Put identification on the shims for assembly purposes.
6. If necessary, remove pin (3) from carrier assembly (2).
7. Bend the tab of the lock from nut (5). Use tool (B) to remove nut (5), the lock and inside nut from the pinion shaft.
8. Remove the pinion shaft from the pinion housing with tooling (C).
9. Remove the small bearing cone and the O-ring seal on the bottom of the pinion housing.
10. Remove the small bearing cup from the pinion housing with tooling (D).
11. Remove the large bearing cup from the pinion housing with tooling (E).
12. Remove the large bearing cone from the pinion shaft with tooling (F).
13. Fasten a hoist to the carrier assembly and turn it over on tooling (A) with the bevel gear up as shown.
14. Remove the lockwire from bolts (6) and (7). Remove bolts (7) and locks (8) from the carrier assembly.
15. Put identification marks on bearing caps (9) and (10).
16. Put a bar through the differential group. Fasten a hoist to the differential group. Make sure nuts (13) and (14) are loose and remove the differential group. The weight of the differential group is 110 lb. (49.5 kg).
17. Remove nuts (13) and (14) and bearing cups (11) and (12). Put identification on bearing cups (11) and (12) for assembly purposes.
18. Put marks on cases (16) and (17) for correct installation and alignment at assembly.
19. Remove bolts (15), the washers and case (16) from case (17).
20. Remove thrust washer (18) and side gear (19).
21. Remove the pinions and spider (20) as a unit from case (17). Remove the thrust washers and pinions from the spider.
22. Remove side gear (21) and the thrust washer from case (17).
23. Bend the tabs of the locks from bolts (22). Remove bolts (22) and the locks from the bottom of case (17).
24. Put a mark on gear (23) and case (17) for correct installation and alignment at assembly. Remove gear (23) from case (17).
25. Remove the bearing cones from cases (16) and (17) with tooling (G).
Assemble Front And Rear Differentials (930 Only)
1. Heat the differential case bearing cones to a maximum temperature of 275°F (135°C). Install the bearing cones to the upper half (1) and lower half of the differential case assembly.
2. Heat gear (3) to a maximum temperature of 250°F (120°C). Install gear (3) on lower case (2).
3. Put oil on the threads of the bolts and the face of the washers that hold gear (3) to case (2). Install the bolts, washers and locks. Tighten all bolts the same amount until they have a torque of 98 ± 5 lb.ft. (134 ± 7 N·m). Bend the tabs of the locks on the bolts.
4. Put oil on the parts of the differential group. Install thrust washer (5) and side gear (4) in case (2) with the oil groove in thrust washer (5) next to side gear (4).
| NOTICE |
|---|
Make a replacement of the thrust washers for the side gears and the thrust washers for the pinions as a set. |
5. Install pinions (7) and thrust washers (6) on spider (8).
6. Install spider (8) in case (2).
7. Install side gear (10) and thrust washer (9) with the groove in the washer next to the gear.
8. Put differential case (1) into position on case (2) with the marks on each case in alignment with each other.
9. Install the washers and bolts to hold the differential cases together. Tighten the bolts to a torque of 100 ± 15 lb.ft. (135 ± 20 N·m).
10. Fasten a hoist to carrier assembly (11) and put it in position on tooling (A) as shown.
11. Install bearing cup (12) on the differential group as shown. Fasten a hoist to the differential group and put it in position in carrier assembly (11).
12. Install bearing cup (14) and bearing cap (13). Make sure the threads in bearing cap (13) and the carrier assembly are in alignment before the bolts are tightened.
13. Install bearing cap (15). Make sure the threads in bearing cap (15) and the carrier assembly are in alignment before the bolts are tightened.
14. Remove the hoist from the differential group.
15. Install lower adjustment nut (16) and upper adjustment nut (17).
16. Lower the temperature of the pinion shaft bearing cups and install them in pinion housing (18).
17. Put clean oil on O-ring seal (19) and install it around housing (18).
18. Heat larger bearing cone (21) to a maximum temperature of 275°F (135°C). Install bearing cone (21) on pinion shaft (20).
19. Put pinion shaft (20) in housing (18). Heat small bearing cone (22) to a maximum temperature of 275°F (135°C). Install bearing cone (22) on pinion shaft (20).
20. Install nut (25), lock (24) and nut (23) on the pinion shaft. Make sure the chamfered edges of the nuts are away from the pinion shaft bearing. Do not tighten nut (20) until the pinion shaft bearing preload has been adjusted.
21. Tighten nut (25) on the pinion shaft until a torque of 6 to 10 lb.in. (0.7 to 1.1 N·m) is needed to turn the pinion shaft. A 1 3/4" socket can be used to turn the pinion shaft.
22. Tighten nut (23) and bend the tab of the lock in the groove of nut (23).
23. Install spring pin (27) and shims (26) equal to the original thickness on carrier assembly (11).
24. Install two 1/2"-13 NC x 6 in. long guide bolts in carrier assembly (11) to hold shims (26) in position.
25. Fasten a hoist to housing (18) and put it in position in the carrier assembly. Install three bolts the same distance apart to hold the housing in the carrier assembly.
26. To make an adjustment of the differential bearing preload and the gear clearance (backlash) between the bevel gear and pinion use the following procedure:
a) Tighten the adjustment nuts until there is a small amount of preload on the bearings.
b) Install tool group (B) on the bevel gear as shown to check the gear clearance (backlash) at four locations around the bevel gear 90° apart. Use the lowest indication on tool group (B) as the correct gear clearance (backlash) value. The correct gear clearance (backlash) is .008 to .013 in. (0.20 to 0.33 mm).
c) If the gear clearance (backlash) is too much, loosen the upper adjustment nut and tighten the lower adjustment nut the same amount to change the gear clearance (backlash). If the gear clearance (backlash) is not enough, loosen the lower adjustment nut and tighten the upper adjustment nut the same amount to change the gear clearance (backlash).
d) Tighten the upper adjustment nut until a torque of 30 to 50 lb.in. (3.4 to 5.7 N·m) is needed to turn the pinion shaft.
e) Check the gear clearance (backlash) again as in Steps b and c.
27. To check the tooth contact setting between bevel gear and pinion after the gear clearance (backlash) and bearing preload adjustments have been made use the following procedure:
a) Put small amount of prussian blue, red lead or paint on bevel gear teeth. Turn pinion and check marks made on bevel gear teeth.
b) With no load, correct tooth contact setting will be as shown. The area of contact starts near toe of gear and goes about 30% up the length of tooth. With this setting, when load is put on gear, it will be over the correct area of teeth.
ALIGNMENT OF BEVEL GEAR AND PINION
CORRECT TOOTH CONTACT SETTING
SHORT TOE CONTACT SETTING
SHORT HEEL CONTACT SETTING
c) If bevel pinion shaft is too far away from bevel gear, short toe contact will be the result as shown. The teeth of pinion will be in contact with toe ends of convex faces (part that makes a curve toward the outside) and top edge of heel end of concave faces (part that makes a curve toward the inside). To correct this, move pinion shaft toward gear by a decrease of the shim thickness between pinion housing and carrier. After this is done, check gear clearance (backlash) and tooth contact again.
d) If bevel shaft is too near to center of bevel gear, short heel contact will be the result as shown. The teeth of pinion will be in contact with toe ends of concave faces (part that makes a curve toward the inside) and the heel ends of convex faces (part that makes a curve toward the outside). To correct this, move pinion shaft away from gear by an increase of the shim thickness between pinion housing and carrier. After this is done, check gear clearance (backlash) and tooth contact again.
NOTE: Several adjustments of both pinion and bevel gear can be needed before correct tooth contact setting and gear clearance (backlash) is made. Always remember that a change to gear clearance (backlash) will also change the tooth contact setting. Be sure gear clearance (backlash) is in correct adjustment before tooth contact is checked.
e) After correct gear clearance (backlash) and tooth contact setting is made, remove extra prussian blue, red lead or paint from bevel gear and pinion.
27. Install locks (28) and bolts for adjusting nuts. Put lockwire on the four bolts for bearing caps. Remove the two guide bolts and install remainder of bolts that hold the housing. Tighten the bolts to a torque of 110 ± 10 lb.ft. (149 ± 14 N·m). Remove differential and carrier assembly from tooling (A). Install the yoke.
end by:
a) install front or rear differential