Usage:
Remove Differential And Carrier
start by:
a) remove rear axle housing and differential
b) remove rear axles
1. Remove plug (2) and its gasket and drain the oil from the differential housing. The capacity of the housing is about 15 U.S. gal. (56.8 liter).
2. Remove the bolts that hold thrust pin cover (1) in position. Remove the cover and the shims from the differential housing.
3. Install a 3/8"-16 NC forged eyebolt in thrust pin (3). Remove the pin from the housing with the O-ring seal from the pin.
4. Put identification on four brake cooling tubes (5) and (6). Remove two bolts (8) that fasten the tube clamps to support (9). Remove the eight tubes from the axle housing.
5. Remove two bolts (13) and (14), washers and lockwashers. Remove block (11), slack adjuster (10) and manifold (12) from the support.
6. Fasten a hoist to support (9) as shown and put the differential in a vertical position. Remove tool (A) from the differential. Put wood blocks (shoring) in position under the rear suspension cylinder mounting points and the stabilizer rod mounting point to hold the axle housing so it will not move.
7. Remove nuts (15) and lockwashers that fasten the support to the axle housing and remove the support. The weight of the support is 650 lb. (293 kg).
8. Remove bolts (17) and washers that fasten the differential to the axle housing. Use three 3/4"-10 NC forcing screws (16) to make a separation of the differential and the axle housing.
9. Remove the forcing screws and install three 3/4"-10 NC forged eyebolts in the differential. Fasten a hoist to the eyebolts and remove the differential from the axle housing. The weight of the differential is 880 lb. (401 kg).
Install Differential And Carrier
1. Inspect the condition of O-ring seal between differential and the axle housing.
2. Install three 3/4"-10 NC forged eyebolts in the differential and fasten a hoist as shown. Install two 3/4"-10 NC guide pins in the axle housing and put the differential in position in the axle housing. The weight of the differential is 880 lb. (401 kg). Install the bolts and lockwashers that fasten the differential to the axle housing.
2. Fasten a hoist to support and put in position on the studs in the axle housing. The weight of the support is 650 lb. (293 kg). Install the nuts and lockwashers that fasten the support to the axle housing. Put SAE 30 oil on the washer, nut face and threads. Tighten the nut to a torque of 1100 ± 100 lb. ft. (1485 ± 135 N·m). Install tool (A) on the differential. Remove the blocks (shoring) and lower the support until tool (A) is on the floor.
3. Fasten manifold (1) and the block on the support with two bolts, washers and lockwashers.
4. Install four brake tubes (2). Install two bolts (4) that fasten the tube clamps to the support. Inspect the O-ring seal on each end of the four brake cooling oil tubes (3) and make a replacement if necessary. Install the four brake cooling tubes.
5. Install O-ring seal (5) on thrust pin (6). Install the thrust pin in the differential housing as shown.
6. Use this procedure to get the correct clearance between the thrust pin and the large bearing cap of the differential and carrier:
a) Install pin cover (7) on the differential housing without any shims. Install the bolts that hold it in position.
b) Tighten the bolts evenly until the pin is against the bearing cap.
c) Use a feeler gauge to measure the distance between the housing and the cover.
d) Make a thickness of shims the same as the distance measured plus .002 ± .001 in. (0.05 ± 0.03 mm).
7. Remove the pin cover, install the shims and the cover and install the bolts that hold these parts in position.
8. Fill the differential to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.
end by:
a) install rear axles
b) install axle housing and differential
Disassemble Differential And Carrier
start by:
a) remove differential and carrier
1. Fasten a hoist to the differential and carrier assembly. Put the differential and carrier assembly in position on tooling (A). Weight of the differential and carrier assembly is 880 lb. (401 kg).
2. Loosen two rings (2) 1/2 turn.
3. Remove four nuts (1). Remove the bearing caps (3).
4. Install a 1 in. (25.4 mm) bar (4) through the differential. Fasten a hoist to the differential and carrier (6) as shown. Weight of the differential and carrier assembly is 400 lb. (181.4 kg).
5. Remove ring and cage assemblies (5).
6. Remove bearing cone (7) with tooling (B).
7. Remove larger bearing cone (8) with tooling (C).
8. Remove eight bolts that hold ring gear and housing assembly (9). Fasten a hoist to the ring gear (9) as shown. Remove the ring gear assembly (9). Weight of the ring gear assembly is 180 lb. (81.6 kg).
9. Remove lockwire and bolts (10) that hold ring gear (12) to housing (11).
10. Install three of the bolts as forcing screws to remove the ring gear (12) from housing (11).
11. Fasten a hoist to the housing (11) as shown. Remove the housing from the ring gear (12). Weight of the housing is 100 lb. (45.4 kg).
12. Remove thrust washers (13) from differential side gear (14). Remove differential side gear (14).
13. Fasten a hoist to the spider and pinion assembly (15). Weight of the spider and pinion assembly is 77 lb. (35 kg). Remove the spider and pinion assembly.
14. Remove thrust washers (16), pinion (17) and bearing (18), from spider (19).
15. Remove side gears (20) and the thrust washer from housing (21).
16. Fasten a hoist to the carrier assembly (23). Put it in position on tooling (A). Weight of the carrier assembly is 380 lb. (172.4 kg).
17. Remove bolts (22) that hold the pinion assembly to the carrier assembly (23). Install two 1/2"-13 NC forcing screws to remove the pinion assembly from the carrier.
18. Install two 1/2"-13 NC forged eyebolts in the pinion. Fasten a hoist to the pinion assembly (24). Remove the pinion assembly. Weight of the pinion assembly is approximately 100 lb. (45.4 kg).
19. Remove the bolts and lock (25) that hold retainer (27) to the pinion shaft. Remove yoke (26).
20. Remove oil slinger (28) and cage (29) from the pinion shaft.
21. Remove spacer (30) and the O-ring seal under the spacer.
22. Remove bearing cones (31) and (32) from the pinion shaft.
23. Remove bearing cup (33) from the carrier.
24. Remove bearing cup (34), seal (35) and O-ring seal (36) from the cage.
Assemble Differential And Carrier
1. Fasten a hoist to the differential housing (1). Weight of the housing is 100 lb. (45.4 kg). Put the housing (1) in position on the ring gear (2). Put washer (4) and side gear (3) in the housing (5).
2. Put 2P2506 Thread Lubricant on the washer faces and bolt threads. Install the bolts that hold the differential housing to the ring gear. Tighten the bolts to a torque of 320 ± 20 lb. ft. (435 ± 25 N·m). Install the lockwire. Use wire to fasten four bolts together.
3. Install bearing (7), pinion (8) and thrust washer (9) on spider (6).
4. Fasten a hoist to the spider assembly (10). Weight of the spider assembly is 77 lb. (35 kg). Put it in position in the differential case.
5. Install differential side gear (11). Install the thrust washer for the differential side gear.
6. Fasten a hoist to the ring gear and differential housing (12). Weight of the ring gear and differential housing is 180 lb. (81 kg). Put the ring gear and differential housing (12) in position on the pinion housing. Tighten the bolts that hold the ring gear and differential housing to the pinion housing to a torque of 290 ± 10 lb. ft. (396 ± 14 N·m). Install the lockwire for each pair of bolts.
NOTE: Make sure the marks that were put on the housing at disassembly are in alignment when installed.
7. Turn the differential with tooling (A). The maximum torque needed to turn the differential two complete revolutions in each direction must not be more than 25 lb. ft. (35 N·m).
8. Heat bearing (13) in oil to a maximum temperature of 275°F (135°C). Install bearing cone (13) as shown.
9. Heat bearing cone (14) in oil to a maximum temperature of 275°F (135°C). Install bearing cone (14) as shown.
10. Install bearing cups (15).
11. Install ring (16) and cage (17) on each side of the differential assembly.
12. Lower the temperature of bearing cup (18). Install it in the carrier assembly.
13. Heat the bearing for the pinion shaft to a maximum temperature of 275° F (135°C). Install the bearing on the pinion shaft.
14. Install a 1/2"-13 NC forged eyebolt in the end of the pinion shaft. Fasten a hoist to the pinion shaft. Weight of the pinion shaft is 65 lb. (29.5 kg). Install the pinion shaft (19) in the carrier assembly.
15. Lower the temperature of the bearing cup and install it in the bearing cage.
NOTE: Do not install the seal at this time.
16. Install a 1/2"-13 NC bolt in the end of the pinion shaft.
17. Install bearing cage (20) on the carrier and install every other bolt as shown.
18. Tighten the bolts evenly and turn the pinion shaft at the same time until a minimum torque of 35 lb. in. (4.0 N·m) is necessary to turn the pinion shaft. Turn the pinion shaft several more times.
19. Use a feeler gauge to measure gap (21) between the carrier and cage (20) at several locations. Take an average of these measurements.
20. Remove cage (20) but do not turn the pinion shaft.
21. Install the correct shim measurement found in Step (19).
22. Install the shims and cage (20) on the carrier with every other bolt. Tighten the bolts to a torque of 35 ± 5 lb. in. (4.0 ± 0.6 N·m) while the pinion shaft is turned. If cage (20) has to be removed to add or remove shims, do not turn pinion shaft. Remove the cage.
23. When the pinion bearing adjustment is correct, use tool (D) to install lip type seal (22) with the lip of the seal toward the inside of the cage as shown. Put clean oil on the lip of the seal.
24. Put clean oil on O-ring seal (23). Install the O-ring seal (23) for the bearing cage. Install spacer (24) with its O-ring seal. Install shim pack (25). Install the bolts that hold the bearing cage to the carrier assembly. Tighten the bolts to a torque of 75 ± 5 lb.ft. (100 ± 7 N·m).
25. Install the yoke, retainer and bolts for the pinion assembly.
26. Fasten a hoist to the differential assembly (27). Weight of the differential assembly is 400 lb. (180 kg). Put the differential assembly on the carrier assembly.
27. Install bearing caps (25). Tighten nuts (26) to a torque of 800 ± 100 lb. ft. (1090 ± 135 N·m). Install the lockwire for each pair of nuts.
28. Put the carrier in position so the centerline for the axles is vertical and the teeth of bevel gear (12) are up. Make adjustment for differential housing preload and for gear clearance (backlash) between ring gear and pinion with the following procedure:
a) Install tooling (C) on the ring gear as shown to check the gear clearance (backlash) at four locations around the ring gear 90° apart. Use the lowest indication on tooling (C) as the correct gear clearance (backlash) value. Turn lower adjusting ring (16) until there is .014 ± .005 in. (0.36 ± 0.13 mm) of clearance (backlash) between ring gear (12) and pinion (19).
b) Install tooling (C) on upper bearing cap (25) and ring gear (12) as shown. Tighten upper adjusting ring (16) until the distance between the ring gear and the bearing cap increases .020 to .025 in. (0.51 to 0.64 mm).
c) Turn the ring gear two complete turns in each direction then loosen the upper adjusting ring until the distance between the ring gear and the bearing cap returns to zero.
d) Tighten the upper adjusting ring until the distance between the ring gear and the bearing cap increases .015 ± .002 in. (0.38 ± 0.05 mm).
e) Install tooling (C) as in Step a and check the clearance (backlash) again between the ring gear and the pinion. The clearance (backlash) must be .014 ± .005 in. (0.36 ± 0.13 mm).
f) If gear clearance (backlash) is too much, loosen upper adjusting ring (16) and tighten lower adjusting ring same amount. If gear clearance (backlash) is not enough, loosen lower ring and tighten upper ring the same amount.
| NOTICE |
|---|
If one adjustment ring is loosened, the other must be tightened the same amount to keep differential bearing preload the same. |
end by:
a) install differential and carrier