Usage:
A. Axle Removal
1. Disconnect hydraulic lines and linkage from hyd. motor. Disconnect shift linkage from gear case.
2. Disconnect brake fluid line.
3. Support vehicle under frame so tires are off floor. Remove wheels.
4. Place floor jack under axle differential housing and remove mounting nuts and bolts. Lower axle with floor jack and remove from under vehicle.
B. Axle Installation
1. Support axle with floor jack under differential housing.
2. Push axle into position under vehicle which must be supported under main frame.
3. Raise axle with floor jack until axle mounting pads are in contact with mounting pads on vehicle. Install U-bolts from under side of axle and install nuts.
4. Mount wheels, raise jack until frame supports can be removed, then lower vehicle to floor.
5. Connect brake fluid lines. Bleed brakes to remove air. Refill master cylinder.
6. Connect hydraulic lines and linkage to motor and bleed systems. Connect shift linkage to gear case.
C. Shaft Removal, Non-Steering Axle
1. Remove planetary cap mounting nut, tapered dowel, planetary cap, and gasket.
2. Pull axle shaft and sun gear assembly from housing.
3. Remove snap ring and sun gear from axle.
D. Shaft Installation, Non-Steering Axle
1. Slide axle shaft into housing. Exercise care when sliding splined end through oil seals or seals may be damaged. When shaft reaches differential side gear, rotate slightly to engage splines.
2. Place sun gear on axle shaft and install snap ring.
3. Place planetary cap and gasket in position and install mounting dowels and nuts.
E. Planetary Disassembly
1. Remove drain plug from drive falnge and drain planetary assembly. Remove nuts, dowels, drive flange and gasket.
(Bronze axle shaft stop may be replaced if badly worn.)
2. Disassemble drive flange by removing socket head capscrews, washers and planet pin key. Remove planet pin; hold planet gear as pin is removed and remove gear and thrust washers from drive flange. Remove needle bearings and inner retainer from gear. Inspect all parts for wear or galling. Inspect steel thrust washers for excessive wear. Inspect planet gear pin for wear or galling. The pin must be completely smooth since it serves as inner race for needle bearings.
3. Remove snap ring, sun gear, and spacer from end of axle shaft. Remove ring gear from spindle.
4. Loosen socket head capscrews and remove bearing locknut from spindle.
5. Remove hub and drum assembly from spindle; inspect seal and bearings for wear.
6. Remove drum mounting bolts to remove brake drum. Inspect inside surface of drum for scratches, grooves, and out-of-roundness. Turn drum if necessary.
7. Remove nuts from spindle mounting bolts.
8. Remove brake assembly and spindle from axle housing. Inspect seal in bore of spindle.
F. Planetary Assembly
1. Mount spindle, brake assembly on spindle mounting bolts and install nuts. Torque to 50-60 ft. lbs.
2. Bolt brake drum to hub. Install inner wheel bearing assembly, oil seal and outer wheel bearing cup in hub.
3. Slide hub into position on spindle. Press outer bearing cone into approximate position and install bearing locknut on spindle. Turn bearing locknut in tight to insure proper seating of wheel bearings. Back off 1/8turn and check to make sure hub rotates freely. Tighten socket head capscrew. Place ring gear in position on spindle.
4. Install spacer on axle shaft. Slide sun gear onto end of axle shaft and install snap ring.
5. Assemble drive flange by installing needle bearings and inner retainer into planet gears. Place planet gears and thrust washers in drive flange and install planet gear pins. Place planet pin keys into correct position and fasten with internal shakeproof washers and socket head capscrews. Make sure that bronze axle shaft stop is firmly seated in drive flange.
6. Slide drive flange assembly into hub, rotating slightly to engage gear teeth. Fasten to hub studs with tapered dowels, and locknut.
7. Turn hub until arrow is pointing down and fill with lubricant until oil runs from check plug hole.
G. Differential Carrier Removal And Disassembly
1. Drain lubricant from differential, remove housing cover and remove axle shafts.
2. Remove carrier-to-housing studs, dowel, and locknuts, and gear case-to-brace bolts-to-gear case bolts and disassemble gear case from carrier assembly.
3. Loosen ring gear thrust pad lock nut and remove thrust pad.
4. Remove differential adjusting nut locks and bearing cap bolts and lockwashers. Remove bearing caps and adjusting nuts by tapping on caps until free from dowels.
5. Remove differential and right gear assembly from carrier housing. Exercise care that differential side bearings are not dropped.
6. Check differential case to make sure the two halves are marked so they will be reassembled in same relation.
7. Remove bolts holding case and cover together.
8. Separate cover from case and remove differential side gears, pinion gears, and differential spider.
9. Wash all parts in cleaning solvent.
10. Inspect ring gear for chipped or worn teeth.
11. Check radial clearance between differential side gears and differential case; also fit of differential pinions on spider.
12. Inspect spider arms for wear and distortion.
13. Inspect splines and teeth of differential side gears and pinions for chipping or excessive wear.
14. Inspect differential side bearings and cups for broken races, discoloration, or roughness.
15. Remove ring gear from case by tapping back of gear with a soft hammer.
16. Inspect ring gear pilot case flange and back of ring gear for dirt or burrs.
17. If ring gear is to be replaced, install two guide pins to new gear diametrically opposite each other.
18. Start guide pins through case flange and tap ring gear onto case.
H. Differential Assembly
1. Lubricate differential side gears and pinions.
2. Place differential pinions on spider.
3. Assemble side gears and pinions to left half of differential case.
4. Assemble right half of differential case to left half, being sure to line up marks on the two halves.
5. Install 10 differential-to-ring gear bolts and lockwashers and tighten evenly until ring gear is flush with case flange.
6. Remove two guide pins and install remaining two bolts. Tighten all bolts to 85-95 ft. lbs.
I. Pinion Disassembly
1. Remove gear case output shaft from pinion. Remove carrier adapter from carrier. Remove output sleeve from pinion.
2. Remove pinion and bearing assembly from carrier.
3. Drive oil seal from carrier adapter. Discard seal as new part should be used at assembly.
5. Press off front double-row bearing assembly.
6. Wash all parts in cleaning solvent.
7. Inspect pinion for cracked, chipped, or worn teeth. Inspect splines for excessive wear.
8. Inspect bearings for excessive wear or discoloration.
J. Pinion Assembly
1. Install double row front pinion bearing assembly onto pinion shaft, using a piece of 2-inch pipe to press against inner row, until the collar on inner race seats against the pinion head.
2. Press rear pinion bearing on the pinion shaft until chamfered side of inner race seats against shoulder on pinion shaft.
3. Install rear pinion bearing and lock ring. Lubricate pinion bearings with engine oil.
4. Install pinion and bearings in carrier, Using new gasket, install carrier adapter on carrier, install mounting bolts and lockwashers and torque to 160-170 ft. lbs.
5. Install gear case output sleeve on pinion shaft. Lubricate oil seal lip and install seal into carrier adapter with seal lip toward pinion bearing.
6. Install gear case output shaft into sleeve.
7. Install pinion mounting bolt thru output shaft into the pinion and torque to 200-220 ft. lbs.
K. Differential Carrier Assembly
1. Mount carrier in bench vise.
2. Lower differential assembly into carrier and install side bearing cups and adjusting nuts.
3. Install differential bearing caps, making sure the marks on the caps line up with marks on the carrier.
4. Install bearing cap bolts and lockwashers, and tighten until lockwashers just flatten out.
5. To adjust ring gear and pinion backlash, loosen differential bearing cap bolts enough to permit turning bearing adjusting nuts. Remove all lash between ring gear and pinion.
6. Back off left-hand adjusting nut one or two notches to a locking position.
7. Tighten right-hand adjusting nut firmly to force differential in solid contact with left-hand adjusting nut.
8. Back off right-hand adjusting nut until free of bearing, then re-tighten snugly against bearing.
9. Tighten right-hand nut from one to two additional notches to a locking position.
10. Mount a dial indicator (Figure 1A) on the carrier and check the backlash between ring gear and pinion. Backlash should be from .008" to .010". If backlash is more than .010", loosen right-hand adjusting nut one notch and tighten left-hand adjusting nut one notch. If backlash is less than .008", loosen left-hand nut one notch and tighten right-hand nut one notch.
11. Tighten bearing cap bolts to 190-220 ft. lbs. Recheck backlash and install both adjusting nut locks.
12. Inspect bronze tip of ring gear thrust pad and if worn, install a new one.
13. Install thrust pad and tighten screw until bronze tip engages back face of ring gear while rotating gear.
14. Back off screw 1/12 turn and tighten locknut to 125-140 ft. lbs. Make sure screw does not turn during locking process. This adjustment provides .005" to .007" clearance between thrust pad and ring gear face.
15. Using new gasket, install gear case onto carrier assembly. Install mounting bolts and lockwashers and torque to 30-35 ft. lbs.
FIGURE 1A
L. Differential Carrier Installation
1. Clean out axle housing and cover, and place new gasket over axle housing.
2. Assemble differential carrier to axle housing. Install studs, dowels, and locknuts, and tighten securely.
3. Install gear case-to-axle housing brace mounting bolts, lockwashers and flat washers and tighten securely.
4. Replace axle housing inspection cover, using new gasket.
5. Make sure drain plug is tightly installed and fill with lubricant.
M. Service Diagnosis
1. Excessive oil deposits at the inside of the wheel indicates leakage past oil seal between hub and spindle or a leaking wheel cylinder. Check operation of pressure relief fitting (7-1/2-15 lb. Alemite) to see that it is functioning properly. To check condition of oil seal, remove hub from spindlw. Replace seal if necessary and polish seal surface on spindle. A leaking wheel cylinder. should be repaired with a wheel cylinder kit.
2. A noisy or wobbly wheel might indicate worn or badly adjusted wheel bearings. Remove hub and inspect bearings. Turn in inner bearing nut until wrench tight, then back off 1/8 turn and check to make sure wheel turns free.
3. Another cause of noise in the wheel might be worn or broken gears in the planetary reduction. Disassemble and check all gears and inspect planet gear needle bearings, pins, and thrust washers. Check mounting of ring gear spider. Replace worn or broken parts.
4. Excessive noise originating at the axle differential area can be caused by any one of several parts being worn or badly adjusted. Remove inspection cover and check backlash between ring gear and pinion. Inspect differential bearings, pinion bearing and condition of all gears. Refer to Section E, F for planetary disassembly & planetary assembly instructions.
5. An obvious break in the power train between the axle pinion and the wheel can be traced by removing the differential inspection cover. Turn the wheels to determine on which side of the differential a shaft or planetary gear failure has occurred.
