Usage:
844 (2KZ),
854G (1JW) Wheel Tractors;
990 (7HK),
990 Series II (4FR),
992C (49Z),
992D (7MJ),
992G (7HR),
994 (9YF),
994D (3TZ) Wheel Loaders
- SUPPLEMENT: APRIL 19, 1999
Service Magazine SEPD0458, Article 19, Page 17 & 18, February 15, 1999; "Rework Procedure Available To Upgrade Differential Case Assembly".
Disregard this article and see Service Magazine SEPD0468, Article 18, Page 14 titled "New Differential Case Assembly And Side Gear Thrust Washers Used".
--------------- END SUPPLEMENT ---------------
- SUPPLEMENT: MARCH 29, 1999
Service Magazine SEPD0458, Article 19, Page 17-18, "Rework Procedure Available To Upgrade Differential Case Assembly".
The 994D (7MJ) Wheel Loader listed in this article is incorrect. The correct model should be 994D (3TZ) Wheel Loader.
--------------- END SUPPLEMENT ---------------
Description of Change: A new differential group replaces the former differential group. This change replaces the former thrust washer, which was held by two dowels with a new thrust washer, held by two screws. The new thrust washer improves the service life of the differential group.
Illustration 1.
120-0550 Differential Group
Adaptable To: The new 120-0550 Differential Group replaces the former 6W-7419 Differential Group (discontinued). This change replaces the former 1V-6317 Thrust Washer (not canceled), which was held by two 3D-6509 Dowels (not canceled), with 9U-3295 Thrust Washer (2), held by two 8C-7562 Screws (1). The new 120-0550 Differential Group is effective with the machines listed in the Table. This change is adaptable to first production for the machines listed by replacing the existing 6W-8261 Differential Case Assembly with a new 120-0551 Differential Case Assembly. If the existing case assembly is not damaged, the case may be upgraded by following the procedure below.
Procedure To Upgrade 6W-8261 Differential Case Assembly
Illustration 2.
6W-8262 Differential Case (Flange Half)
Illustration 3.
6W-8263 Differential Case (Plain Half)
1. Remove the differential. Refer to your Disassembly and Assembly Manual for instructions on removing and installing the differential.
2. Remove 3D-6509 Dowels (5) from the 6W-8262 Differential Case and 6W-8263 Differential Case or carefully grind the dowels to a smooth surface finish.
Illustration 4.
9U-3295 Thrust Washer
3. Position two new threaded holes (6) on each differential case away from dowels (5) that were ground in Step 2. Use 9U-3295 Thrust Washer (2) as a template for these holes.
4. Drill the holes to a diameter of 7 mm (.28 in) and to a depth of 24 mm (.94 in). Counterbore the holes to a diameter of 12 ± 1 mm (.47 ± .039 in) and a depth of 3.5 ± .5 mm (.138 ± .020 in). Tap each hole: M8 X 1.25-6H THD to a depth of 18 mm (.71 in).
5. Clean all contact surfaces with a solvent cleaner.
6. Apply a thin layer of Retaining Compound to the face of the differential case where the thrust washer will contact.
NOTE: 4C-9506 Retaining Compound is a 10 ml (.33 oz.) container. 4C-9507 is a 50 ml (1.67 oz.) container.
7. Install the 9U-3295 Thrust Washer with the flat surface against the case.
8. Apply a sufficient amount of Retaining Compound to each 8C-7562 Screw in order to lock the threads and bond the screw head to the thrust washer.
9. Tighten each screw to a torque of 12 ± 3 N·m (8.8 ± 2.2 lb ft). Do not over tighten the screws.
10. Clean off excess retaining compound.