Usage:
Axle Input Components
(1) Housing. (2) Shims. (3) Snap ring. (4) Rear bearing. (5) Stud. (6) Pinion shaft. (7) Inner bearing cone. (8) Inner bearing cup. (9) Gasket. (10) Bearing cage. (11) Spacer. (12) Outer bearing cup. (13) Outer bearing cone. (14) Seal. (15) Gasket. (16) Cover. (17) Deflector. (18) Input flange. (19) Washer. (20) Nut.
Disassemble Axle Input End
Start by:
a. disassemble axle housing
1. Attach a holding tool to input flange (18). Hold to prevent pinion shaft (6) from turning in the following step.
2. Remove nut (20) and washer (19) from the end of the pinion shaft.
3. Use a puller to remove input flange (18) from the axle. Do not use a hammer to loosen the flange. This could damage components of the axle.
4. Remove deflector (17).
5. Remove nuts and washers securing cover (16) to housing (1).
6. Remove cover (16). Tap the cover with a plastic hammer, if necessary to loosen it.
7. Press seal (14) from cover (16). Discard seal (14) and gasket (15). These will be replaced with new parts during assembly.
8. Clean out three threaded puller holes in bearing cage (10). Install 7/16 - 14 bolts into the puller holes and tighten alternately to loosen the bearing cage assembly.
| NOTICE |
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Do not use a pry bar to remove the bearing cage from the housing. This could damage the bearing cage, shims, and housing. |
9. Remove bearing cage (10) and pinion shaft (6) assembly from the housing.
10. Remove gasket (9) and discard. This will be replaced with a new part during assembly.
11. Remove shims (2). If the shims are damaged, they will have to be discarded and replaced with new parts. Measure the total thickness of the shim pack with a micrometer. Note this figure for use during assembly.
12. Examine studs (5) in housing (1). Remove any damaged studs and replace with new parts.
13. Support the pinion shaft and bearing cage assembly with blocks, as illustrated. Press pinion shaft (6) out through bearing cage (10). Outer bearing cone (13) and two bearing cups (12) and (8) will remain inside the bearing cage. Inner bearing cone (7) will remain on the pinion shaft.
14. Remove bearing spacer (11).
15. Remove outer bearing cone (13) from inside bearing cage (10).
16. Examine bearing cups (12) and (8) inside bearing cage (10). If the bearing cups appear damaged, they must be removed from the bearing cage, as shown.
17. Examine inner bearing cone (7) on pinion shaft (6). If the bearing cone appears damaged, it must be removed with a bearing puller or press, as shown.
NOTE: Keep bearing cup and cone sets together. This will help ensure that these parts are reassembled in their original positions.
17. Remove snap ring (3) from end of pinion shaft (6).
18. Use a bearing puller to remove rear bearing (4) from pinion shaft (6).
| NOTICE |
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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. |
19. Housing (1) may be cleaned in a hot solution tank with a mild alkali solution. The housing should remain in the tank long enough to be heated through. Rinse and dry the housing thoroughly 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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20. All other parts should be cleaned with a suitable solvent such as kerosene or diesel fuel. Do not clean parts with gasoline.
21. Dry parts immediately after cleaning. Do not dry bearings by spinning with compressed air.
22. 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.
23. Lubricate bearing cups and cones with a coat of light oil.
Assemble Axle Input End
1. If removed, press inner bearing cup (8) and outer bearing cup (12) into bearing cage (10). Make sure both bearing cups are flat against the bore.
2. If removed, press inner bearing cone (7) onto pinion shaft (6). Use a sleeve against the inner race of the bearing cone, as shown. Make sure the bearing cone is seated squarely against the pinion gear head.
3. Press rear bearing (4) onto pinion shaft (6). Make sure the bearing is seated flat against the pinion gear head.
4. Install snap ring (3) into the groove at the end of pinion shaft (6). This will secure rear bearing (4).
5. Insert pinion shaft (6) assembly into bearing cage (10).
6. Install bearing spacer (11) on pinion shaft (6) against inner bearing cone (7).
7. Install outer bearing cone (13) into bearing cage (10). Place a sleeve against the inner race of the bearing and press with 11 350 kg (25,000 lbs.) of force. Rotate the bearing cage while pressing, to seat the bearings.
8. Check the rolling resistance of the pinion bearings as follows:
a. Press input flange (18) onto the splined end of pinion shaft (6). Make sure the input flange is against outer bearing cone (13).
b. Place the pinion shaft and bearing cage assembly onto the housing. Do not install shims or gaskets at this time.
c. Hand tighten nuts onto studs (5) to secure the pinion shaft and bearing cage assembly to the axle housing. Washers are not needed.
d. Attach a holding tool to input flange (18). Hold to prevent pinion shaft (6) from turning in the following step.
e. Install washer (19) and nut (20) to the end of the pinion shaft. Tighten the nut to 271 to 373 N·m (200 to 275 lb. ft.).
f. Use a torque wrench to rotate the pinion shaft as shown. The value indicated on the torque wrench is the rolling resistance of the bearings.
g. The rolling resistance in step f should be .6 to 1.7 N·m (5 to 15 lb. in.). Rolling resistance can be increased or decreased by tightening or loosening nut (20) within 271 to 373 N·m (200 to 275 lb. ft.).
9. If rolling resistance is not correct, pinion shaft (6) and bearing cage (10) assembly must be disassembled. Replace bearing spacer (11) with a thinner spacer to increase the resistance. Replace bearing spacer (11) with a thicker space to reduce the resistance
10. Repeat steps 7 through 9 until rolling resistance is correct.
11. Remove nut (20) and washer (19) from the end of the pinion shaft.
12. Remove input flange (18) from the bearing cage assembly.
13. Lift the pinion shaft and bearing cage assembly off of the housing.
14. Install shims (2) on housing (1). Align the oil slots in the shims with oil slots in the axle housing. If the pinion shaft and ring gear set is being replaced with new parts, the thickness of the shim pack may have to be changed, as follows:
a. Record the thickness of the old shim pack that was removed from the axle during disassembly.
b. Record the PC variation number on the old pinion shaft being replaced. The PC number is located on the end of the pinion shaft, as shown above.
NOTE: The PC variation number could represent inches or millimeters. A PC number of +3 or -3 indicates .003 in.. A PC number of +.03 or -.03 indicates .03 mm.
c. If the PC number on the old pinion shaft is a plus (+) value, subtract it from the original shim pack thickness. If the PC number is a minus (-) value, add it to the original shim pack thickness.
d. Record the PC variation number on the new pinion shaft. If this PC number is a plus (+) value, add it to the number found in step c. If the PC number is a minus (-) value, subtract it from the number found in step c.
e. The number calculated in step d is the required thickness of the new shim pack to be installed.
NOTE: Use a minimum of three shims in a pack. If the pack is made from different thickness shims, install the thinnest shims on both sides of the pack for maximum sealing.
14. Install a new gasket (9) on top of shims (2).
15. Install the pinion shaft and bearing cage assembly onto the housing. If necessary, use a rubber hammer to seat the assembly.
16. Coat the outer metal edge of a new seal (14) with a non-hardening sealing compound. Grease the lips and inside cavities of the new seal.
17. Press seal (14) into cover (16), as shown. Make sure the seal is fully seated, and is square with the cover.
18. Install a new gasket (15) and cover (16) over the bearing cage. Align the oil slots in the cover and gasket with the oil slot in the bearing cage.
19. Secure cover (16) with washers and nuts. Tighten the nuts to 149 to 224 N·m (110 to 165 lb. ft.).
20. Install deflector (17) over cover (16).
21. Press input flange (18) onto the end of the pinion shaft. Make sure the input flange is against the outer bearing cone inside the bearing cage.
22. Attach a holding tool to input flange (18). Hold to prevent pinion shaft (6) from turning in the following step.
23. Install washer (19) and nut (20) to the end of the pinion shaft. Tighten the nut to 271 to 373 N·m (200 to 275 lb. ft.).
24. Use a torque wrench to recheck the rolling resistance of the pinion shaft bearings. If the torque is not .6 to 1.7 N·m (5 to 15 lb. in.), tighten or loosen nut (20) within specifications to adjust the rolling resistance.
End by:
a. assemble axle housing