Usage:
Start By:
a. remove steering housing
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
NOTE: Front axle removed for better photographic illustration
1. Remove oil plug (1) and drain oil in a suitable container.
2. Loosen bolts (2) and separate axle housing (3) from housing (4).
3. Pull differential (5) out of the axle housing (4).
4. Remove O-ring (6) from axle housing (3). Replace O-ring if necessary at assembly.
5. Remove bearing outer race (7) using Tooling (A) from axle housing (3).
6. Remove two tapered roller bearings (8) from differential using Tooling (B).
7. Remove socket head screws (9).
NOTE: When the crown wheel is separated form the differential case the differential will fall.
8. Press crown wheel from the differential case, using three screws as shown.
9. Lift upper plate pack (10) along with side gear out of the differential case (11).
10. Drive roll pin (12) in the differential shaft (13).
11. Drive out differential shaft (13).
12. Remove differential bevel pinions, thrust washers and second plate pack (14) along with side gear from differential case (11).
NOTE: The following steps are for the assemble of the differential.
13. Place thrust plate, outer and inner plates upon the side gear.
NOTE: Coated surface of thrust plate is facing the outer plate. Pay attention to an equal thickness of the two clutch packs. Insert pre-assembled side gear in the differential case (11).
14. Insert the two differential bevel pinions (15) with thrust plates and fix them by means of the differential shaft (13).
NOTE: Pay attention to the radial installation position of the thrust washer as well as the installation position of the differential shaft.
15. Use an indicator and check end play of the plate pack. In the case of deviations from the prescribed end play of 0.2 mm (.008 in), correct with corresponding outer plates. The height of the two plate packs must be equal on either side of the differential shaft. Remove components again after completion of the adjustment. Oil all differential components with oil being lubricated and insert them again in the differential case and fix by means of differential shaft. Fix differential shaft by means of a roll pin. Drive roll pin half way in the differential shaft.
16. Press crown wheel (16) on the differential case (11) and install socket head screws (9). Put 9S-3263 Thread Lock of the threads and tighten to a torque of 68 N·m (51 lb ft).
17. Heat the two tapered roller bearings (8) to 135 °C (275 °F) and press them firmly against the shoulder.
18. Insert 2.0 mm (.08 in) shim (17) in the bearing bore of the axle housing and install subsequent bearing outer race (18).
19. Insert the bearing outer race (19) in the measuring device Tooling (C) on the crown wheel side.
20. Insert differential (5) in the axle housing (4).
21. Install Tooling (C) and apply dial indicator as shown and check for backlash.
NOTE: The backlash of the differential ring gear is controlled by shim (17) located behind the bearing cup (18) in the axle housing (4).
22. Move the handle of Tooling (C) up and down to obtain the backlash of the differential ring gear. Record this dimension. The backlash of the differential ring gear should be 0.07 - 0.22 mm (.003 - .008 in). To increase the amount of backlash, install a thinner shim (17). To decrease the amount of backlash, install a thicker shim (17). If backlash value is not correct, repeat steps 18 through 21.
23. After completion of the backlash adjustment. Remove measuring device Tooling (C).
24. Determine dimension (U) [from face of bore Tooling (C) to the bearing cup seating surface of Tooling (C)] dimension (U) 65.30 mm (2.57 in).
25. Determine dimension (V) (from the face of the bore in Tooling (C) to the to the outer ring flange) dimension (V)69.75 mm (2.746 in).
26. Determine dimension (W) (from the inner machined surface of the axle housing (3) to the seat face for the bearing cup as shown) dimension (W)62.50 mm (2.461 in).
27. Determine dimension (X) (from the inner machined surface of the axle housing (3) to the flange mounting surface as shown) dimension (X)65.55 mm (2.581 in).
28. Calculation:
NOTE: A bearing preload of 0.10 mm (.004 in) (empirical value) give the required bearing rolling movement of 1 to 4 N·m (9 to 35 lb in).
29. Insert 1.50 mm (.059 in) shim (17) in the bore of axle housing (3) and install subsequent bearing outer race (18) until contact is obtained.
30. Check contact pattern, backlash and bearing preload. Cover some crown wheel teeth flanks with gear-marking compound and insert differential (5) in the axle housing (4).
31. Install axle housing (3) in position and temporarily install several bolts and washers.
Illustration
Illustration
Illustration
32. Turn the pinion gear assembly in both directions. Remove axle housing (3). Carefully remove differential (5) from the axle housing (4). Check tooth contact pattern. The correct area of tooth contact starts near the inside end of the teeth on the ring gear and goes a maximum of 50 percent down the length of the teeth. See illustration 1 for the correct area of tooth contact.
33. If the area of tooth contact looks like illustration 2, add shims behind bearing cup for the pinion gear assembly in the axle housing (4). Repeat steps 30 through 32 to check the tooth contact pattern.
34. If the area of tooth contact looks like illustration 3, remove shims behind bearing cup for the pinion gear assembly in the axle housing (4). Repeat steps 30 through 32.
35. NOTE: Always make sure the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash may be necessary to obtain the proper results.
36. Install bolts and washers (22) and tighten to a torque of 185 N·m (135 lb ft).
End By:
a. install steering housing