Usage:
Axle Housing Components
(1) Spacers. (2) Bearing cups. (3) Bearing cones. (4) Differential (5) Ring gear. (6) Slotted nut. (7) Cotter pin. (8) Washer. (9) Drive flange. (10) Seal. (11) Snap ring. (12) Spacer. (13) Bearing. (14) Axle shaft. (15) Housing. (16) Drain plug. (17) Gasket. (18) Cover. (19) Stud. (20) Pin. (21) Thrust block.
Disassemble Axle Housing
NOTE: The entire axle assembly may be steam cleaned on the outside only, providing all openings are closed. Breathers and any other openings must be tightly covered to prevent water from entering the axle.
1. Wash the exterior of the axle with mineral spirits or solvent. Perform the disassembly in a clean work area.
2. Remove drain plug (16) to drain lubricant from the axle. Replace the plug after lubricant has drained.
3. Remove cotter pin (7) from slotted nut (6) and axle shaft (14) on one side of the axle.
4. Remove slotted nut (6) and washer (8) from the end of the axle shaft.
5. Use a puller to remove drive flange (9) from the end of the axle shaft.
6. Remove seal (10) from inside drive flange (9).
7. Use a screw driver or snap ring tool to work snap ring (11) out of its groove inside axle housing (15).
8. Pull axle shaft (14) with installed spacer (12) and bearing (13) straight out of the axle.
9. Pull spacer (12) and bearing (13) off of the axle shaft.
10. Repeat steps 3 through 9 to remove components from the other end of the axle.
11. Insert a length of pipe, slightly smaller than the diameter of the axle shaft, through axle housing (15). This will support differential (4) and ring gear (5) in the following steps.
12. Remove nuts, bolts, and washers securing cover (18) to housing (15).
13. Carefully pull cover (18) away from housing (15). Make sure the differential assembly is supported by the pipe. Discard gasket (17). This will be replaced with a new part during assembly.
14. Slide differential (4) and ring gear (5) assembly off of the pipe. Remove the pipe from housing (15).
15. Examine bearing cups (2) and bearing cones (3) for damage. Perform steps 16 and 17 only if these parts need to be replaced.
16. Pull two bearing cones (3) off of differential (4).
17. Pull two bearing cups (2) and spacers (1) from the axle cover and housing. Wire spacers (1) to their respective bearing cups (2) to keep these parts together.
NOTE: Keep bearing cup and cone sets together. This will help ensure that these parts are reassembled in their original positions.
18. Examine studs (19) in housing (15). Remove any damaged studs and replace with new parts.
19. Remove thrust block (21) and pin (20) from cover (18).
20. Ring gear (5) may be secured to differential (4) with bolts or rivets. If ring gear needs to be replaced, perform the following steps to separate the ring gear from the differential.
a. If the ring gear is secured with bolts, remove bolts, washers, and nuts, as shown.
b. If the ring gear is secured with rivets, center punch the rivet heads on the ring gear side of the assembly.
c. Use a drill .76 mm (.03 in.) smaller than body of rivet to drill through each rivet head, as shown.
d. Press rivets out and discard.
e. Support the ring gear with blocks, as shown. Press the case out through the ring gear.
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Pinion shaft and ring gear are a matched set. If damaged or worn out, these parts must be replaced as a set. |
NOTE: Disassemble axle input end before cleaning housing (15).
20. The axle housing and cover may be cleaned in a hot solution tank with a mild alkali solution. The parts should remain in the tank long enough to be heated through. The parts should be thoroughly rinsed and dried after cleaning to remove all traces of alkali.
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Exercise care to avoid skin rashes and inhalation of vapors when using alkali cleaners. |
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21. All other parts should be cleaned with a suitable solvent such as kerosene or diesel fuel. Do not clean parts with gasoline.
22. Dry parts immediately after cleaning. Do not dry bearings by spinning with compressed air.
23. Inspect all parts for excessive wear or damage. Make sure bearings rotate smoothly. Check all splines and gear teeth for burrs or other damage. Repair or replace parts as necessary.
24. Lubricate bearing cups and cones with a coat of light oil.
Assemble Axle Housing
| NOTICE |
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Do not press a cold ring gear onto the differential assembly. If the ring gear is not heated per the following step, the tight fit will cause excessive gear runout in the axle assembly. |
1. Heat ring gear (5) in water to a temperature of 71° to 82°C (160° to 180°F). The ring gear should remain in the hot water for 10 to 15 minutes so it will be thoroughly heated.
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Wear safe clothing and gloves to protect against injury when handling the hot ring gear in the following steps. |
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2. Install the ring gear to the differential assembly immediately after heating. If the ring gear does not fit easily on the differential, repeat step 1.
NOTE: Use either bolts or rivets to secure the ring gear to the differential assembly, regardless of original construction. The part numbers for these fasteners are located in the Parts Book for the machine.
3. Secure the ring gear to the differential assembly as follows, if bolts, washers, and nuts are used.
a. Install bolts, washers, and nuts through the ring gear and differential. The bolt heads must be against the ring gear.
b. Tighten the bolts.
c. Use a .08 mm (.003 in.) feeler gauge to check the gap between ring gear (5) and differential flange (4). Check at four equally spaced points around the assembly. If the gauge can be inserted more than half of distance (22), the ring gear must be removed. Find and correct the problem and reinstall the ring gear to meet the above specification.
4. Secure the ring gear to the differential assembly as follows, if rivets are used.
a. Install cold rivets in pairs opposite each other from the differential side of the assembly. The rivet heads must be against the differential flange.
b. Press the rivets into place from the ring gear side of the assembly. See the following chart to find the force needed to install the rivets. Hold force on rivets for one minute.
c. Use a .08 mm (.003 in.) feeler gauge to check the gap between ring gear (5) and differential flange (4). Check at four equally spaced points around the assembly. If the gauge can be inserted more than half of distance (22), the ring gear must be removed. Find and correct the problem and reinstall the ring gear to meet the above specification.
5. Press two bearing cones (3) onto the differential assembly. Make sure the bearing cones are seated squarely against the differential housing.
6. If removed, install spacers (1) into the axle cover and housing. The chamfered edge of the spacers must face the machined surface of the axle cover and housing.
7. If removed, press one bearing cup (2) into axle housing (15). Press the remaining bearing cup (2) into axle housing (18). Make sure both bearing cups are seated squarely.
8. Insert a length of pipe, slightly smaller than the diameter of the axle shaft, through axle housing (15). This will support the differential assembly in the following steps.
9. Measure the gear lash between the ring gear and the pinion shaft, as follows:
NOTE: Axle input end must be assembled to perform the following steps.
a. Slide the differential and ring gear assembly onto the pipe and into housing (15).
b. Temporarily install cover (18) onto the axle housing. Do not install gasket at this time. Secure with six equally spaced nuts and bolts.
c. Use a dial indicator to measure gear lash at the input flange, 50 mm (2 in.) from the center of the pinion shaft.
d. Remove cover (18) and the differential and ring gear assembly from the axle housing.
e. An indicator reading of .33 to .84 mm (.013 to .033 in.) indicates the correct gear lash of .15 to .30 mm (.006 to .012 in.) at the gear set.
f. If gear lash is incorrect, spacers (1) in the axle cover and housing will have to be replaced with thicker or thinner spaceers, as follows.
g. Increase gear lash by using a thicker spacer in the housing (15) half of the axle. Decrease the thickness of the spacer in the cover (18) half by the same amount. This will move the ring gear away from the pinion shaft.
h. Decrease gear lash by using a thinner spacer in the housing (15) half of the axle. Increase the thickness of the spacer in the cover (18) half by the same amount. This will move the ring gear toward the pinion shaft.
10. Check the contact of ring gear teeth with pinion shaft teeth, as follows:
NOTE: Axle input end must be assembled to perform the following steps:
a. Paint about 12 of the ring gear teeth with a commercial marking compound. Slide the differential and ring gear assembly onto the pipe and into housing (15).
b. Temporarily install cover (18) onto the axle housing. Do not install gasket at this time. Secure with six equally spaced nuts and bolts.
c. Rotate pinion shaft (23) forward and backward so the painted gear teeth go past the pinion shaft six times. This will mark the contact pattern on the ring gear.
d. Remove cover (18) and the differential and ring gear assembly from the axle housing. Examine the contact pattern on the ring gear teeth.
e. A good contact pattern should appear as above. Contact should be toward the toe of the gear, and centered between the top and bottom of the tooth.
f. If the pinion shaft is not installed deep enough into the axle, a high contact pattern will appear, like above. The pinion shaft and bearing cage assembly (part of the axle input assembly) will have to be removed. Decrease the thickness of the shim pack under the bearing cage.
g. If the pinion shaft is installed too deep into the axle, a low contact pattern will appear, like above. The pinion shaft and bearing cage assembly (part of the axle input assembly) will have to be removed. Increase the thickness of the shim pack under the bearing cage.
h. Repeat steps a through g until tooth contact is correct. Remove excess marking compound from gear teeth.
11. Slide the differential and ring gear assembly onto the pipe and into housing (15).
12. Install thrust block (21) and pin (20) into axle cover (18).
13. Install a new gasket (17) over studs (19).
14. Install cover (18) onto the axle housing. Secure with nuts, bolts, and washers. Remove the pipe from inside the axle.
15. Insert one axle shaft (14) into one side of the axle. Make sure the splines at the end of the axle shaft engage the splines of the differential.
16. Press bearing (13) onto axle shaft (14) inside the axle. Press the bearing until it reaches the shoulder on the axle shaft.
17. Install spacer (12) and snap ring (11) over the axle shaft. Make sure snap ring (11) is seated in the groove inside the axle.
18. Coat the outer metal edge of a new seal (10) with a non-hardening sealing compound. Grease the lips and inside cavities of the new seal.
19. Press seal (10) into drive flange (9). Make sure the seal is seated squarely.
20. Install drive flange (9) over the end of axle shaft (14). Use care to prevent damaging the seal.
21. Secure drive flange (9) with washer (8) and slotted nut (6). After tightening, slots on nut (6) must be positioned to allow installation of pin (7).
22. Install cotter pin (7) through slots in nut (6) and end of axle shaft (14).
23. Repeat steps 15 through 22 to install components to the other end of the axle.
24. Add lubricant to the axle. Refer to the Operation and Maintenance Manual for lubricant type and quantity.