Usage:
Start By:
a. Remove the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove" for the machine that is being serviced.
1. Position the differential and bevel gear on Tooling (A), as shown.
2. Remove yoke assembly (1) from the pinion shaft.
3. Secure Tooling (B) to pinion housing (3). Attach a hoist and suitable lifting slings to Tooling (B).
4. Remove sixteen bolts (2) and the washers.
5. Use two bolts (2) to force pinion housing (3) from the carrier assembly.
6. Use the hoist to remove pinion housing (3) from the carrier assembly.
7. Remove shim pack (4).
8. Remove Tooling (B), remaining four bolts (5) and the washers.
9. Remove retainer (6).
10. Remove O-ring seal (7) and lip seal (8) from retainer (6).
11. Straighten the staked area of retaining nut (9). Use Tooling (C) to remove nut (9) from pinion shaft (10).
12. Remove washer (11) from pinion shaft (10).
13. Use Tooling (D) to remove pinion shaft (10) from the pinion housing.
14. Use Tooling (E) and a spacer (12) to remove bearing cone (13) from pinion shaft (10).
15. Remove bearing cone (14) from the pinion housing.
16. Remove bearing cup (15) from the pinion housing.
17. Remove bearing cup (16) and O-ring seal (17) from the opposite end of the pinion housing.
18. Secure Tooling (F) to the differential, as shown. Attach a hoist and suitable lifting slings to Tooling (F).
19. Use the hoist to position the carrier and the differential assembly on Tooling (A). The combined weight of the carrier and the differential assembly is 305 kg (670 lb).
NOTE: Put identification marks on bearing caps (22) and (25) for installation purposes.
20. Remove bearing locks (18) and (19) from the bearing caps.
21. Remove adjustment rings (20) and (21) from each side of the differential.
22. Remove two bolts (22), the washers and bearing cap (23.)
23. Remove two bolts (24), the washers and bearing cap (25).
24. Remove bearing cups (26) and (27).
25. Use Tooling (F) and the hoist to remove differential and bevel gear (28) from carrier (29). The weight of the differential and bevel gear is 130 kg (285 lb).
26. Use Tooling (G) to remove bearing cone (30) from the differential.
27. Put alignment marks across case (32) and case assembly (33) for installation purposes.
28. Remove twelve bolts (31) and the washers.
29. Remove case (32) from case assembly (33).
30. Remove thrust washer (34) from gear (35).
31. Remove gear (35) from the differential.
32. Remove spider (36) and the gear assemblies from case assembly (33).
33. Remove four thrust washer (39), four gears (38) and four sleeve bearings (37) from spider (36).
34. Remove gear (40) and thrust washer (41) from case assembly (41) from case assembly (33).
35. Turn the differential and bevel gear to the opposite end. Place the differential and bevel gear on wood blocks, as shown.
36. Remove 24 bolts (42) and the washers.
37. Attach a hoist and suitable lifting slings to case assembly (33), as shown. Use the hoist to carefully remove case assembly (33) from the bevel gear. The weight of the case assembly is 39 kg (86 lb)
38. Use Tooling (G) to remove bearing cone (43) from the case assembly.