Usage:
NOTE: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacements.
1. Use the proper equipment to handle bearing cone (43). Heat bearing cone (43) to a maximum temperature of 135°C (275°F). Install bearing cone (43) on case assembly (33).
2. Install two 5/8 inch - 18 NF guide pins (45) in bevel gear (44), as shown.
3. Attach a hoist and suitable lifting slings to case assembly (33). Use the hoist to carefully install case assembly (33) to bevel gear (44). The weight of the case assembly is 39 kg (86 lb).
4. Install 24 bolts (42) and the washers. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
5. Turn the differential and bevel gear to the opposite end. Install thrust washer (41) and gear (40) in case assembly (33).
6. Install four sleeve bearings (37), four gears (38) and four thrust washers (39) on spider (36).
7. Install spider (36) and the gear assemblies in case assembly (33).
8. Install gear (35) in the case assembly.
9. Install thrust washer (34) on gear (35).
NOTE: Align the marks on case (32) and case assemblies (33).
10. Install case (32) on case assembly (33).
11. Install twelve bolts (31) and the washers. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
12. Use the proper equipment to handle bearing cone (30). Heat bearing cone (30) to a maximum temperature of 135°C (275°F). Install bearing cone (30) on case (32)
13. Install O-ring seal (17) on the pinion housing.
14. Use the proper equipment to handle bearing cup (16). Lower the temperature of bearing cup (16). Install bearing cup (16) in the pinion housing, as shown.
15. Use the proper equipment to handle bearing cup (15). Lower the temperature of bearing cup (15). Turn the pinion housing to the opposite end. Install bearing cup (15) in the pinion housing, as shown.
NOTE: Allow the bearing cups and the pinion housing to reach a uniform temperature.
16. Use a suitable driver to reset the bearing cups. This will ensure that the bearing cups are seated against the shoulders of the pinion housing.
17. Apply clean oil to the bearing cups.
18. Use the proper equipment to handle bearing cone (13). Heat bearing code (13) to a maximum temperature of 135°C (275°F). Install bearing cone (13) on pinion shaft (10).
NOTE: Allow the bearing cone and the pinion shaft to reach a uniform temperature.
19. Use a hammer and a punch to reset the bearing cone around the inside race of the bearing. This will ensure that the bearing cone is seated against the shoulder of the pinion shaft.
20. Apply clean oil to bearing cone (13).
21. Fasten Tooling (B) to the pinion housing, as shown. Attach a hoist and suitable lifting slings to Tooling (B).
22. Use the hoist to lower the pinion housing on the pinion shaft.
23. Use the proper equipment to handle cone (14). Heat bearing cone (14) to a maximum temperature of 135°C (275°F). Install bearing cone (14) on pinion shaft (10).
NOTE: DO NOT reset bearing cone (14) at this time.
24. Apply clean oil to bearing cone (14).
25. Install washer (11) on pinion shaft (10).
26. Install retaining nut (9) on pinion shaft (10).
27. Use Tooling (C) to tighten retaining nut (9) in order to load the bearings.
28. Attach Tooling (G) to yoke assembly (1). Install yoke assembly (1) and Tooling (G) on the pinion shaft.
29. Use a torque wrench and Tooling (G) to slowly turn the pinion shaft. Check the rolling torque.
NOTE: The proper rolling torque is 1.2 to 3.15 N·m (10 to 28 lb in) for new bearings. If the existing bearings are used, limit the rolling torque to half of the specification.
NOTE: If the rolling torque exceeds the specification, back off the shaft by a 1/8 turn. Reseat the bearings and repeat Steps 28 and 29.
NOTE: Use 0.6 to 1.7 N·m (5.34 to 15.13 lb in) preload torque for machines with more than 100 hours of operation.
(H) The spherical radius of the tool for peening must be 7.5 to 8.0 mm (0.295 to 0.315 inch).
(J) The acceptable angle of the tool for peening is 20 ± 10 degrees.
(K) The minimum length of the crimp is 4.7 mm (0.185 inch).
(L) The minimum depth of the crimp is 2.5 mm (0.098 inch).
(M) Top view.
Completed Stake
NOTE: Before you stake the nut, make sure that the pinion shaft has zero end play.
30. When the rolling torque is correct, stake nut (9) by peening the collar in the slot in pinion shaft (10). See the above illustration and the caption for the correct dimensions.
31. Use Tooling (E) to install lip seal (8) in retainer (6). Make sure that the sealing lip is facing inward. Apply clean oil to the lip seal.
32. Install O-ring seal (7) on the opposite side of retainer (6).
33. Install retainer (6) on the pinion housing.
34. Install Tooling (B) on the pinion housing, as shown. Install four bolts (5) and the washers
35. Install Tooling (F) to differential and bevel gear (28). Attach a hoist and suitable lifting slings to Tooling (F).
36. Use the hoist to carefully install differential and bevel gear (28) to carrier (29). The weight of the differential and bevel gear is 130 kg (285 lb).
37. Apply clean oil to bearing cups (26) and (27). Install bearing cups (26) and (27) in the carrier assembly, as shown.
38. Install bearing cap (25), two bolts (24) and the washers. DO NOT tighten bolts (24) at this time.
39. Install bearing cap (23), two bolts (22) and the washers. DO NOT tighten bolts (22) at this time.
40. Install adjustment rings (20) and (21) in each side of the differential.
41. Tighten bolts (22) and (24) to a torque of 25 N·m (18 lb ft). This will allow adjustment rings (20) and (12) to move freely.
NOTE: Adjust the bearing preload and the gear backlash after the pinion housing has been installed.
42. Use a hoist and suitable lifting slings to reposition the carrier on Tooling (A). The weight of the carrier and the differential assembly is 305 kg (670 lb).
NOTE: If the pinion housing or the carrier housing are being replaced, install 80 percent of a new shim pack as a starting point for the pinion depth adjustment.
43. Install original shim pack (4) between the carrier and the pinion housing.
44. Use a hoist and suitable lifting slings to carefully install pinion housing (3) on the carrier, as shown.
45. Make sure that backlash is present prior to securing pinion housing (3) to the carrier. Install sixteen bolts (2) and the washers. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
46. Replace Tooling (B) with two bolts (5) and the washers.
47. Install yoke assembly (1) on the pinion shaft.
48. Move adjustment rings (20) and (21) on the carrier to a position that maintains gear backlash and slight bearing end play.
49. Install Tooling (G) on yoke assembly (1), as shown. Use a torque wrench and Tooling (G) to slowly turn yoke assembly (1). Check the overall rolling torque with no bearing load on the differential bearings. Record the measured torque.
50. Oscillate the bevel gear and advance adjustment ring (20). Continue to advance the adjustment ring until there is no backlash. Back off the adjustment ring by 1/2 a turn.
51. Advance adjustment ring (21) and check the rolling torque on the pinion shaft. Continue to advance the adjustment ring until the rolling torque is greater than the torque value that was measured in Step 49. This is the seated position.
52. Advance adjustment ring (21) by three additional lugs to the nearest lock position.
53. Mount Tooling (D) on the carrier, as shown. Measure the backlash at four places on the bevel gear at 90 degree intervals. Compare the lowest reading to the specifications. The proper backlash setting is 0.36 ± 0.13 mm (.014 ± 0.005 inch).
54. If the backlash is not within the specification, retract one adjustment ring and advance the opposite adjustment ring equally. This will maintain the bearing preload. Recheck the bearing preload.
NOTE: When the proper backlash has been obtained, tighten the bearing cap bolts. The bearing cap bolts have different torque values. Make sure that the proper torque is applied.
55. Tighten two bearing cap bolts (22) to a torque of 1800 ± 200 N·m (1325 ± 150 lb ft).
56. Tighten two bearing cap bolts (24) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
57. Use a torque wrench and Tooling (G) to measure the overall rolling torque at the pinion shaft. The rolling torque must be 3.1 to 11.4 N·m (27.44 to 100.90 lb inch).
Illustration A
58. After the backlash adjustment and the preload adjustment have been made, the tooth contact between the pinion shaft and bevel gear (44) must be checked. Use the following procedure:
a. Put a small amount of Prussian blue, red led, or paint on three or four adjacent teeth of bevel gear (44).
b. Rotate the pinion shaft for several revolutions in one direction. Then rotate the pinion shaft for several revolutions in the opposite direction. Then turn the pinion shaft in the original direction in order to observe the marked teeth.
c. The correct area of tooth contact begins near the inside end of the teeth. The contact area should extend to a maximum of 50 percent of the length of the teeth. See Illustration A for the correct area of tooth contact.
Illustration B
59. If the tooth contact looks like the marks in Illustration B, perform the following procedure:
a. Remove some of the shims that are behind the pinion housing.
b. Repeat Steps 53 through 56 for the backlash adjustment.
c. Repeat Step 59.c in order to check the overall rolling torque at the pinion shaft.
Illustration C
60. If the tooth contact looks like the marks in Illustration C, perform the following procedure:
a. Add shims behind the pinion housing.
b. Repeat Steps 53 through 56 for the backlash adjustment.
c. Repeat Steps 59.c in order to check the overall rolling torque at the pinion shaft.
NOTE: Always make sure that the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash and to the tooth contact may be necessary in order to achieve the correct adjustments. A change to gear backlash will also change the gear contact and vice versa.
61. After the adjustments are made, remove any dyes or paint from the gears.
62. Install bearing locks (18) and (19) and the bolts on the bearing caps, as shown.
End By:
a. Install the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install" for the machine that is being serviced.