Usage:
Start By:
a. remove differential (front)
1. Put front axle housing assembly (1) in position on tooling (A).
2. Loosen nut (2); then carefully hit the balljoint end of the tie rod to remove it from the steering knuckle.
3. Fasten tool (B) to final drive carrier. Remove kingpin assemblies (3).
4. Pull the final drive carrier and knuckle assembly away from the axle housing arm. Remove sealing caps and bearings (4) from the axle housing arm. Remove the carrier and knuckle assembly completely. Weight is 60 kg (132 lb).
5. Follow Steps 2 through 4 for the other end of the axle housing.
6. Put the axle housing in position on wood blocks. Install tool (C). Remove bolts (6) and differential assembly (5). Weight is 34 kg (75 lb).
7. Put the differential assembly in position in tool (D). Remove lockpin (7) from the carrier.
8. Use tool (E) to remove nuts (8). Remove the bearing cups. Do this procedure on both ends of the carrier.
9. Assemble tooling (F) as shown in Illustration C8866P1. Use it to remove the bearing from the bevel gear end of the differential carrier.
10. Assemble tooling (G) in the same manner as tooling (F). Use it to remove the bearing from the end opposite the bevel gear.
11. Put location marks on the differential case halves. Tilt the differential assembly to allow access to Allen head bolts (9). Remove bolts (9) and plates (10).
12. Separate the differential case halves. Remove gears (11) and the washers.
13. Remove the differential case halves from the carrier.
14. Remove lock (13), nut (12) and the washer from the pinion.
15. Put the differential carrier in position in a press.
16. Press the pinion from the yoke. Be careful not to let the pinion drop to the floor.
17. Remove yoke (14).
18. Remove seal (15) and bearing (16).
19. Remove bearing races (17) from the carrier.
20. Remove collapsible spacer (18) from the pinion assembly.
21. Use tool (H) and a press to remove bearing (19) from the pinion.
Assemble Differential (Front) (Open Gear)
NOTE: The pinion depth procedure is only necessary if the pinion and bevel gear set or carrier is to be replaced.
1. Measure the bore radius of the differential bearing supports. This will be Dimension A, which is 44.96 mm (1.770 in).
2. Drill two 3/16" holes in a piece of 25 mm (1 in) diameter bar stock that is 254 mm (10 in) long. Drill the two holes (one on each end) 76 mm (3 in) away from each end of the bar stock.
3. Put tool (A) in the bar stock. Put tool (A) along with the bar stock in position in the differential carrier as shown. Measure from the top of the bar stock to the bearing race seat surface. Add this dimension to Dimension A. The combination of dimensions will be Dimension B, which is 154.75 mm (6.093 in).
4. Measure the diameter of the bar stock. Subtract this dimension from Dimension B. This dimension will be Dimension C, which is 129.35 mm (5.094 in).
5. Measure the thickness of the bearing and race as an assembled unit. Subtract this dimension from Dimension C. This dimension will be Dimension D which is 99.07 mm (3.901 in).
6. Dimension D is the distance from the centerline of the axles to the bearing locating shoulder of the pinion.
NOTE: Stamped on the end of the pinion is the nominal dimension, [97.92 mm (3.855 in)]. Etched on the end of the pinion is the deviation from the nominal dimension [-0.1 mm (-.004 in)]. Also etched on the end of the pinion is an identification number for the pinion and bevel gear set.
7. Add the deviation to the nominal dimension. This will be the actual pinion dimension, [97.82 mm (3.851 in)]. Example: 97.92 mm + (-0.1 mm) = 97.82 mm [3.855 in + (-.004 in) = 3.851 in].
8. From Dimension D subtract the actual pinion dimension. This will be 1.27 mm (.05 in) which is the shim thickness required.
9. Install required shim (2). Lower the temperature of bearing races (1), and install them in the differential carrier.
10. Heat bearing (3) to a temperature of 135°C (275°F), and install it on the pinion.
11. Put the pinion in position in the differential, and install collapsible spacer (4).
12. Heat bearing (5) to a temperature of 135°C (275°F), and install it in the differential carrier bore.
13. Put a mixture of 50% water and 50% alcohol on the outside diameter of seal (6). Use a suitable piece of tubing, and install seal (6) in the differential carrier.
14. Install yoke (8), washer (9) and nut (7). Tighten nut (7) to a torque of 300 to 350 N·m (220 to 260 lb ft). Then, increase torque until the pinion rolling torque of 2 to 3 N·m (18 to 27 lb in) is achieved.
15. Put lock (11) in position on the nut. Use tool (F) to drive the lock over the nut. Round off the end of a piece of 5/16" drill rod (10), and stake the lock to the yoke in two locations.
16. Put thrust washer (13) and side gear (12) in position in the differential case half.
17. Check the backlash with tooling (B) on each differential case half. The backlash should be 0.20 to 0.30 mm (.008 to .012 in).
18. Put the differential case halves in position in the carrier. Position bevel gear to the left side of the pinion when facing the pinion flange. Note the position of tabs (14) on the thrust washers. They should be in the "UP" position as shown.
19. Put the differential case halves together, and make sure the location marks are in alignment on each case half.
20. Install plates (16) and bolts (15). Tighten the bolts to a torque of 150 N·m (110 lb ft).
21. Heat both large and small bearings to a temperature of 135°C (275°F), and install them on the case halves (large bearing on bevel gear end and small bearing on the opposite end).
22. Install bearing races (18) and nuts (17).
23. With the differential assembly in the position shown, tighten the bottom nut until a backlash of 0.010 to 0.250 mm (.0004 to .0098 in) is obtained.
NOTE: Rotate the differential several times during this procedure.
24. Tighten the top nut with tool (C) until there is no bearing end play. Tighten the top nut an additional two lugs.
25. Use tool (B) to check the backlash again. Adjust the nuts the same amount in opposite directions until the backlash is 0.010 to 0.25 mm (.0004 to .0098 in).
26. Install lockpins (19). Make sure the pins are below surface (X).
27. Check the bevel gear runout with tool (B). The permissible amount is 0.080 mm (.0031 in).
28. Make sure the mating surfaces of the differential assembly and axle housing are clean and free of dirt.
29. Put 6V6640 Gasket Maker on the axle housing surface. Fasten tool (E) and a hoist to the differential assembly. Put differential assembly (20) in position over the axle housing. Be sure the differential housing is in alignment with hollow dowels (21).
30. Install differential assembly (20) on the axle housing, and install the bolts that hold it. Install the longer of the bolts in the hollow dowels. Tighten the bolts to a torque of 250 N·m (185 lb ft).
31. Put the axle assembly in position on tooling (D). Install bearing (22) and the sealing cap in the axle housing arm. The lower bearing and sealing cap will have to be held in place while the steering knuckle and final drive assembly is being installed. Put 2S3230 Bearing Lubricant on the bearings.
32. Fasten tool (E) and a hoist to the steering knuckle and final drive assembly (23). Put the assembly in position on the axle arm.
33. Install O-ring seals (25), shim (26) [top kingpin only] and kingpin (24). Install the bolts that hold the kingpin.
34. Install the bottom kingpin.
35. Check the rolling torque. Rolling torque should be 10 to 12 N·m (90 to 108 lb in).
36. Put the tie rod balljoint in position on the steering knuckle. Install nut (27). Tighten the nut to a torque of 300 N·m (220 lb ft). Install cotter pin (28).
End By:
a. install differential (front)