Procedure to Machine Damaged Transmission and Differential Yokes {3030, 3253, 3258} Caterpillar


Procedure to Machine Damaged Transmission and Differential Yokes {3030, 3253, 3258}

Usage:

MT700 018
Agricultural Tractor
All
Articulated Truck
All
Backhoe Loader
All
Compact Wheel Loader
All
Integrated Toolcarrier
All
Landfill Compactor
816K (S/N: LT61-UP; SLL1-UP)
826K (S/N: 2L31-UP; 2T61-UP)
836K (S/N: T6X1-UP; L6Z1-UP)
Motor Grader
All
Off-Highway Truck/Tractor
69D (S/N: 9SS1-UP; 9XS1-UP)
73D (S/N: 9YS1-UP; 1GW1-UP)
768B (S/N: 79S1-UP)
768C (S/N: 02X1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)
770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-UP)
772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
772D (S/N: 5HR1-UP)
772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; LTS1-UP; KEX1-UP; LTX1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 5SC1-UP; 63W1-UP)
773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP; 7FZ1-UP)
773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
773F (S/N: EED1-UP; EXD1-UP)
773GC (S/N: RJZ1-UP)
776 (S/N: 14H1-UP; 14W1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP; 3NF1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: DCB1-UP; AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP; 6XZ1-UP)
777E (S/N: KDP1-UP; KDZ1-UP)
777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)
777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
779 (S/N: 45H1-UP)
783B (S/N: 8YM1-UP)
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
785G (S/N: SH21-UP; MS41-UP; TRG1-UP; RTL1-UP; WHS1-UP)
786 (S/N: 01A1-UP; 80A1-UP; 81A1-UP)
787B (S/N: 9TM1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)
789G (S/N: TR21-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)
796 (S/N: HRP1-UP; HRY1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)
798 (S/N: ST71-UP)
Paving Compactor
All
Pipelayer
All
Quarry Truck
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)
Road Reclaimer/Soil Stabilizer
All
Soil Compactor
815K (S/N: SL91-UP; T1Y1-UP)
825K (S/N: 2L91-UP; 2T91-UP)
Telehandler
All
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Wheel Dozer
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All

Introduction

Table 1
Revision  Summary of Changes in SEBF8048 
21  Added new serial number prefixes for New Product Introduction (NPI).
Tables arranged in alpha numeric sequence.
Table 6 divided in to 8 tables. Each table is now with the corresponding illustration.
Added Illustration 34 to the "Metal Spray Method to Repair Seal Surfaces" section.
Added 8 part numbers.
The 110-2141 Yoke dimension "B" has been updated with the correct dimension.  
20  Added new serial number prefixes for New Product Introduction (NPI).
Added 4 part numbers.
Added content from SEBF2152, "Thermal Spray Procedures for Transmission and Torque Converter Yokes". 
19  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018. 
18  Added 4 part numbers. 
17  Added 16 part numbers. 

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information



Illustration 1g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.


Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.



Illustration 2g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline provides the procedures necessary to determine the reusability of the (insert component name). Life will vary depending on application, load, lubrication, and environment.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse. Follow visual inspections and the "Crack Detection Methods" section for further guidance.

Note: Illustrations in this guideline may appear different from some of the components. While the illustrations are typical, the dimensions are actual. All the dimensions that are listed are dimensions for manufacturing and assembling a new machine.

References

Table 2
References 
Media Number  Publication Type & Title 
Channel1  "Why Reuse and Salvage Parts" 
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
PERJ1017  Special Publication"Dealer Service Tools Catalog" 
SEBF8187  Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures" 
SEBF9236  Reuse and Salvage Guidelines
"Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning Components" (1) 
SEBF9238  Reuse and Salvage Guidelines
"Fundamentals of Arc Spray for reconditioning Components" (1) 
SEBF9240  Reuse and Salvage Guidelines
"Fundamentals of Flame Spray for Reconditioning Components" (1) 
(1) Only Cat dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment and always use the correct equipment for all processes in each Thermal Spray Application.

Service Advisories, Service Letters, and Technical Service Bulletins


NOTICE

The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.


Tooling and Equipment


NOTICE

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components.

To avoid component damage, follow the recommended procedure using the recommended tools.


Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

Table 3
Required Tooling and Equipment 
Part Number  Description  Designation 
(1)  Personal Protective Equipment (PPE)  Personal Protection 
1S-0258  Plastic Hammer Assembly  General Tooling 
1U-7262  Telescoping Magnet  General Tooling 
1U-9367  Automatic Tape Measure (1-inch X 26- ft)
25.4- mm x 8- m 
Measurement
Checks 
4S-9405  Caliper
304.8 mm (12.00 inch) 
Profile
Measurement 
5P-3920  Tool
Rule
304.8 mm (12.00 inch) 
Measurement
Checks 
8H-8581  Feeler Gauge
0.038 - 0.635 mm
(0.0015 - 0.0250 inch) 
Thickness
Measurement
Checks 
385-9422  Tools (Micrometer)
Internal
(2 - 24 inch) 
Internal
Measurement
Checks 
386-3364  Tool (Ruler)
1,000.0 mm (39.37 inch) 
Measurement
Checks 
431-4150  Micrometers
External
0 - 25 mm (0 - 1 inch) 
External
Measurement
Checks 
473-8688
or
473-8689 
Instrument Group
Micrometer, Inside
2.00 - 12.00 inch 
Internal
Measurement
Checks 
Instrument Group
Micrometer, Inside
50 - 300 mm
473-8690  Instrument Group
Micrometer, Outside
0.00 - 4.00 inch 
External
Measurement
Checks 
473-8691  Instrument Group
Micrometer, Outside
2.00 - 6.00 inch 
External
Measurement
Checks 
473-8692  Instrument Group
Micrometer, Outside - Digital
152.4 - 304.8 mm (6.00 - 12.00 inch) 
External
Measurement
Checks 
474-3709
or
474-3710 
Instrument Group
Micrometer, Inside
(8.00 - 32.00 inch) 
Internal
Measurement
Checks 
Instrument Group
Micrometer, Inside
200 - 800 mm

and /or
— 
GO/NO-GO Thread Gauge Set, Metric  Threaded Hole
Inspection 
GO/NO-GO Thread Gauge Set, SAE
(1)  Plastic Plug Assortment  Threaded Hole
Protection 
(1)  Tap and Die Set  Threaded Hole
/ Restore 
1U-5516  Disc (Coarse)  Surface
Preparation
/ De-burring 
1U-5518  Threaded Shaft  Surface
Preparation
/ De-burring 
1U-5519  Holder (Disc Pad)  Surface
Preparation
/ De-burring 
4C-8514  Wheel
(2 x 1 inch)
(60 Grit) 
Surface
Preparation
/ De-burring 
4C-8515  Grinding Wheel (F-Grade)
(2 x 1 inch)
(120 Grit) 
Surface
Preparation
/ De-burring 
4C-8521  Wheel Adapter  Surface
Preparation
/ De-burring 
222-3076  Die Grinder
(Right Angle) 
Surface
Preparation
/ De-burring 
254-5319  Brush
76.2 x 50.8 mm
(3.00 x 2.00 inch) 
Surface
Preparation
/ De-burring 
9U-7377 (2)  Metal Marking Pen  Parts Marking 
1U-9918  Brush  General Cleaning 
8T-7765  Surface Reconditioning Pad (180 Grit)  General Cleaning 
162-5791  Towel  General Cleaning 
—  Paint Primer  Sleeve Installation 
6V-6193  Diagonal Cutter  Sleeve Installation 
—  Compound (Retaining)  Sleeve Installation 
213-1983  Pliers  Sleeve Installation 
8T-5096  Tool Group
Dial Indicator 
Run-Out Checks 
7H-1940  Universal Attachment (90°)  Total Indicator Reading (TIR) checks 
9S-8903  Indicator Contact Point  Total Indicator Reading (TIR) checks 
9A-1593  Comparison Gauge (Surface Texture)  Surface Texture
Tester 
453-5376  Tool
Specimen 
Surface Texture
Tester 
448-3698  Indicator
(Profilometer) 
Surface Texture
Tester 
5P-7414  Seal Pick
Kit 
Gear/ Shaft
Step Inspection 
8S-2257  Magnifying Glass  Visual Surface
Inspection (VT) 
9U-6182  Mirror (Telescoping)  Visual Surface
Inspection (VT) 
9U-7231  Flashing Lights Conversion Kit  Visual Surface
Inspection (VT) 
4C-9442  Light  Visual Surface
Inspection (VT) 
(1)  Bright Incandescent Light  Visual Surface
Inspection (VT) 
—  Reflective Surface for Inspection  Visual Surface
Inspection (VT) 
262-8390  Microscope (40-Power)
Pocket 
Crack/
Measurement
Inspection 
288-4209  Paper Towel  Liquid Penetrant
Testing (PT) 
1U-9915  Brush
Curved Handle Wire 
General Cleaning/
Liquid Penetrant
Testing (PT) 
—  Developer  Liquid Penetrant
Testing (PT) 
—  Penetrating Oil  Liquid Penetrant
Testing (PT) 
—  Solvent Cleaner  General Cleaning/
Liquid Penetrant
Testing (PT) 
263-7184  Crack Detection Kit (Magnetic Particle)  Dry Magnetic
Particle Testing
(MPT) 
—  Paint Pen  Dry Magnetic
Particle Testing
(MPT) 
459-0184  Lamp Group
Ultraviolet 
Wet Magnetic
Particle Testing
(MPT) 
(1) Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2) Available in the United States only.

Prepare the Area for Inspection

------ WARNING! ------

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.


------ WARNING! ------

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.




Illustration 3g03794147
Typical burr removal Tooling.
(A) Die Grinder, Right Angle
(B) Wheel Grinder, Group
(C) Conditioning Discs, Disc pad Holder, and Threaded Shaft
(D) Flapper Wheel

  • Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.

  • When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

  • During cleaning, do not damage machined surfaces.

  • Use pressurized air to dry parts.

  • If component cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

  • Use appropriate thread taps to chase all threaded holes.

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part.


NOTICE

Do not use numbering stamp punches to mark internal components. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure.




Illustration 4g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1



Illustration 5g03856853
Typical Example

Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2



Illustration 6g03856857
Typical Example

Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 6. In this example, the gear has a total of 22,000 hours.

Example 3



Illustration 7g03519882
Typical Example

(A) Mark the planet pin on either end.

Parts Reusability



Illustration 8g02319654
Yoke face
(1) Fretting
(2) Slot


Illustration 9g02319655
Yoke face (close view)
(1) Fretting

Transmission and differential yokes can be damaged by the fretting of the yoke face during normal operation. Illustration 8 and Illustration 9 show typical examples of fretting.

After machining the face of the yoke flat, OK TO USE THIS PART AGAIN.

If there is heavy fretting in the slot area, DO NOT USE THIS PART AGAIN.



Illustration 10g02319695
The darker line of wear around the center of the shaft is caused by the lip-type seal.
(3) Wear groove

Transmission and differential yokes can also be damaged by wear of the yoke shaft. The lip-type seals cause wear on the seal contact area of the shaft. “Wear” is defined as being able to feel a step in the seal contact area, as shown in Illustration 10.

If shaft damage is found, Caterpillar recommends machining the yoke face first, if necessary. Then repair the shaft damage.

Procedure to Machine Yoke Faces

  1. Clean and inspect the yoke thoroughly. If there is any wear of the yoke shaft, refer to the "Repairing Shaft Seal Wear" section.


    Illustration 11g02319697
    (A) Diameter

  2. Carefully install the yoke in a lathe to prevent damage to the seal surface. Use diameter (A) as the surface for the chuck jaws.


    Illustration 12g02319733
    Yoke installed in a lathe chuck

  3. Use a dial indicator equipped with a 7H-1940 Universal Attachment (90°) to check the Total Indicator Reading (TIR) of an area of the yoke face that is not worn. Refer to Illustration 12. The maximum TIR for the yoke face is 0.13 mm (0.005 inch).


    Illustration 13g02319914
    Cutting tools and holder necessary to machine yoke faces.

  4. Use a triangular type carbide/ceramic cutting tool to machine the yoke face, as shown in Illustration 13. Turn large pieces approximately 50 rpm and smaller pieces between 150 and 180 rpm. Use a feed-rate of between 0.13 mm/rev and 0.36 mm/rev (0.005 inches/rev and 0.014 inches/rev) for both sizes.

  5. As the yoke face is machined, make sure that all nicks, pits, and debris are removed.

    If more than 0.51 mm (0.020 inch) of material is removed, then DO NOT USE THIS PART AGAIN.



    Illustration 14g02319915
    Machined yoke face.

  6. Feel the surface texture with your finger. If the machining grooves cannot be felt, the surface texture is acceptable. If the machining grooves can be felt, use a surface texture analyzer to determine if the surface texture is acceptable. The maximum allowable surface texture is 6.35 µm (250 µinch) or smoother. Refer to Illustration 14.


    NOTICE

    To reduce fretting in the future, be sure to remove any paint on the contact surfaces of both the yoke and any part fastened to the yoke before installing the yoke on the transmission or differential. Also, tighten all bolts to the correct torque.


  7. To prevent corrosion, put a thin layer of rust inhibitor or oil on the yoke.

    Note: Ensure that the oil or rust inhibitor is removed prior to installation.

Repairing Shaft Seal Wear

Lip-type seals can cause a groove to wear in the contact surface of the mating part. Many times this part could be used again except for the groove wear. Wear sleeves are now available to install over the groove to give a new seal surface to the worn part. The wear sleeve will allow reuse of the worn part and allow the use of the original seal part number. This guideline gives the part numbers of the wear sleeves, the sleeve drivers (installation tools), and the procedure needed to make the repair. Table 4 gives the part number of the sleeve to install according to the size of the shaft. Table 5 provides the part number of the sleeve according to the part number of the yoke or flange being repaired.

Wear Sleeves and Wear Sleeve Drivers



Illustration 15g02319987
(4) Rolled surface
(5) Driver
(6) Driver
(7) Driver

Driver (6) has rolled surface (4).

There is a specific driver to use for installation of each wear sleeve. The drivers are all either a type (5), (6), or (7) as shown in Illustration 15. The type (5) and type (7) drivers have a closed end (shown) and an open end (not shown). These two drivers can be used in only one way to install a wear sleeve. To use type (6) drivers (open on both ends), always put the end that has the rolled (round) part (4), next to the sleeve.



Illustration 16g02321214

Illustration 16 shows a typical wear sleeve. The wear sleeve is made in one piece and has a wear surface (9) for the seal, and a flange (8). In most applications of the wear sleeve, the flange will be removed.

Table 4
Application Chart by Reference to Shaft Size 
Shaft Size  Sleeve Part Number  Sleeve Driver 
19.81 mm to 19.91 mm (0.780 inch to 0.784 inch)  5P-6158  5P-6195 
22.17 mm to 22.28 mm (0.873 inch to 0.877 inch)  5P-6159  5P-6195 
22.94 mm to 25.04 mm (0.903 inch to 0.986 inch)  5P-6160  5P-6196 
25.35 mm to 25.45 mm (0.998 inch to 1.002 inch)  5P-6161  5P-6196 
26.92 mm to 27.03 mm (1.060 inch to 1.064 inch)  5P-6162  5P-6197 
27.94 mm to 28.04 mm (1.100 inch to 1.104 inch)  5P-6163  5P-6197 
28.52 mm to 28.63 mm (1.123 inch to 1.127 inch)  5P-6164  5P-6198 
29.31 mm to 29.41 mm (1.154 inch to 1.158 inch)  5P-6165  5P-6198 
31.67 mm to 31.83 mm (1.249 inch to 1.253 inch)  5P-6166  5P-6198 
34.85 mm to 35.00 mm (1.372 inch to 1.378 inch)  5P-6167(1)  5P-6199 
34.85 mm to 35.00 mm (1.372 inch to 1.378 inch)  5P-6168(1)  5P-6199 
36.45 mm to 36.60 mm (1.435 inch to 1.441 inch)  5P-6169  5P-6200 
38.02 mm to 38.18 mm (1.497 inch to 1.503 inch)  5P-6170  5P-6200 
41.20 mm to 41.35 mm (1.622 inch to 1.628 inch)  5P-6148(2)  5P-6149 
41.20 mm to 41.35 mm (1.622 inch to 1.628 inch)  5P-6171(2)  5P-6149 
42.80 mm to 42.95 mm (1.685 inch to 1.691 inch)  5P-6172  5P-6150 
44.37 mm to 44.53 mm (1.747 inch to 1.753 inch)  5P-6173  5P-6150 
47.55 mm to 47.70 mm (1.872 inch to 1.878 inch)  4C-6257  5P-6151 
48.49 mm to 48.64 mm (1.909 inch to 1.915 inch)  5P-6174  5P-6151 
49.12 mm to 49.28 mm (1.934 inch to 1.940 inch)  5P-6175  5P-6151 
49.91 mm to 50.06 mm (1.965 inch to 1.971 inch)  4C-6258  5P-6151 
53.90 mm to 54.05 mm (2.122 inch to 2.128 inch)  5P-6176  5P-6201 
60.25 mm to 60.40 mm (2.372 inch to 2.378 inch)  5P-6177  5P-6201 
61.85 mm to 62.00 mm (2.435 inch to 2.445 inch)  5P-6178  5P-6201 
63.47 mm to 63.63 mm (2.499 inch to 2.505 inch)  5P-6179  5P-6201 
65.00 mm to 65.15 mm (2.559 inch to 2.565 inch)  5P-6180  5P-6202 
66.60 mm to 66.75 mm (2.622 inch to 2.628 inch)  5P-6181  5P-6202 
69.77 mm to 69.93 mm (2.747 inch to 2.753 inch)  5P-6182  5P-6203 
72.95 mm to 73.10 mm (2.872 inch to 2.878 inch)  5P-6183  5P-6204 
76.12 mm to 76.28 mm (2.997 inch to 3.003 inch)  5P-6184  5P-6204 
79.30 mm to 79.45 mm (3.122 inch to 3.128 inch)  5P-6185  5P-6205 
82.47 mm to 82.63 mm (3.247 inch to 3.253 inch)  5P-6186  5P-6206 
88.93 mm to 89.08 mm (3.501 inch to 3.507 inch)  5P-6187  5P-6207 
90.42 mm to 90.58 mm (3.560 inch to 3.566 inch)  4C-6259  5P-6208 
91.87 mm to 92.02 mm (3.617 inch to 3.623 inch)  5P-6188  5P-6208 
93.60 mm to 93.75 mm (3.685 inch to 3.691 inch)  5P-6189  5P-6208 
95.15 mm to 95.30 mm (3.746 inch to 3.752 inch)  4C-6260  5P-6208 
101.50 mm to 101.70 mm (3.996 inch to 4.004 inch)  5P-6190  5P-6209 
107.90 mm to 108.10 mm (4.248 inch to 4.256 inch)  4C-6261  4C-6742 
114.20 mm to 114.40 mm (4.496 inch to 4.504 inch)  5P-6191  5P-6210 
120.55 mm to 120.75 mm (4.746 inch to 4.754 inch)  4C-6262  4C-6743 
123.72 mm to 123.93 mm (4.871 inch to 4.879 inch)  5P-6192  5P-6211 
126.95 mm to 127.15 mm (4.998 inch to 5.006 inch)  4C-6263  4C-6744 
157.43 mm to 157.68 mm (6.198 inch to 6.208 inch)  5P-6193  5P-6212 
189.08 mm to 189.33 mm (7.444 inch to 7.454 inch)  5P-6194  5P-6213 
(1) Two wear sleeves available: Width of 5P-6167 Wear Sleeve is 15.88 mm (0.625 inch) and 5P-6168 Wear Sleeve is 11.13 mm (0.438 inch).
(2) Two wear sleeves available: Width of 5P-6148 Wear Sleeve is 11.13 mm (0.438 inch) and 5P-6171 Wear Sleeve is 17.48 mm (0.688 inch).

Note: If a wear sleeve is not available, refer to the "Metal Spray Method to Repair Seal Surfaces" section.

Table 5
Seal Surface Repair Sleeves
(by reference to yoke/flange part number) 
Yoke Assembly  Yoke/Flange  Sleeve Part Number(1) 
—  1J-0768  5P-6180 
—  1P-0318  5P-6184 
—  1P-6683  5P-6182 
—  1P-6688  5P-6181 
1P-7522  1P-7521  5P-6184 
—  1S-1532  5P-6184 
—  1S-8541  5P-6192 
—  1T-1386  5P-6184 
—  1T-1565  4C-6261 
8P-0514  1V-8565  5P-6190 
—  2D-2618  5P-6181 
—  2D-9203  4C-6260 
—  2K-3632  5P-6183 
—  2K-5129  5P-6184 
—  2K-5977  5P-6184 
2P-3633  2P-3632  5P-6182 
—  2P-4392  5P-6184 
4C-1677, 193-4589  2P-9155, 193-7146  5P-6184 
—  2R-0975  5P-6190 
2S-3180  2S-3179  4C-6260 
104-6497  2U-9436  5P-6190 
—  2V-5418  4C-6263 
—  2V-7058  5P-6185 
—  2V-7083  5P-6185 
—  2V-7170  5P-6190 
—  3J-5312  5P-6177 
—  3P-3205  5P-6182 
—  3P-3207  5P-6181 
—  3P-3208  5P-6177 
—  3P-3450  5P-6185 
—  3P-3452  5P-6184 
—  3P-3504, 173-0713  5P-6190 
—  3P-5672  5P-6184 
323-2169  3P-8143  5P-6178 
—  3S-7921  5P-6190 
—  3S-9879  5P-6190 
—  3S-9911  5P-6190 
—  3T-0017  4C-6260 
3T-2256  3T-0018  5P-6185 
—  3T-3966  5P-6184 
—  3T-4953  5P-6181 
3T-4955  3T-4954  5P-6181 
3T-5430  3T-5429  5P-6185 
3T-5432  3T-5431  5P-6185 
—  3T-8304  5P-6172 
—  3T-8903  5P-6178 
—  3T-9287  5P-6178 
—  3W-5606  — 
—  4D-1939  4C-6260 
—  4D-7934  5P-6191 
—  4H-3648  5P-6179 
—  4H-6931  5P-6190 
—  4H-8475  5P-6180 
—  4K-5086  5P-6182 
—  4K-7556  5P-6185 
—  4M-3110  5P-6185 
—  4U-1688  5P-6184 
—  4U-6482  5P-6184 
—  4U-6981  5P-6184 
—  5B-8200  4C-6260 
—  5D-6029  5P-6180 
—  5D-6133  5P-6186 
—  5K-0228  5P-6185 
—  5K-4386  5P-6185 
—  5M-7199  5P-6180 
—  5M-7342  5P-6181 
—  5S-0951  5P-6184 
—  5S-0952  5P-6184 
—  5U-4371  5P-6184 
—  5U-4372  5P-6185 
—  5V-2539  5P-6185 
—  5V-3733  5P-6185 
—  5V-6325  5P-6185 
—  5V-6327  — 
5V-6328  5V-6329  5P-6185 
—  5V-8975  5P-6185 
7I-4187  5V-7581  5P-6183 
6G-8197  6G-8198  5P-6183 
6I-8053  6I-8052  5P-6184 
—  6K-4363  5P-6185 
—  6K-4598  5P-6184 
—  6K-4600  5P-6184 
—  6K-5899  5P-6185 
—  6K-7355  5P-6185 
—  6K-7357  5P-6185 
—  6P-8623  5P-6177 
—  6P-8628  5P-6184 
—  6S-0286  5P-6190 
—  6S-3158  5P-6183 
—  6S-5978  5P-6183 
—  6S-6043  5P-6182 
7T-3370  6T-8409  5P-6185 
—  6T-9231  5P-6187 
—  6T-9233  5P-6187 
—  6T-9576  5P-6182 
107-5610  6W-4281  4C-6261 
6Y-6638  6Y-6630  — 
6Y-6637  6Y-6631  — 
6Y-6636  6Y-6633  4C-6263 
6Y-8137  6Y-7138  4C-6263 
—  6Y-8158  5P-6182 
—  6Y-8972  5P-6185 
—  6Y-9644  5P-6176 
7G-1139  7G-1161  — 
—  7G-3495  5P-6180 
—  7G-6896  — 
159-1847  7I-3893  5P-6184 
—  7I-4186  5P-6184 
—  7K-0395  5P-6185 
—  7K-0438  5P-6185 
—  7K-0767  5P-6190 
3K-9917, 7K-1261  3K-9663, 7K-1261  5P-6190 
—  7K-7616  5P-6187 
—  7M-5933  5P-6184 
—  7T-2821  5P-6185 
—  7T-2822  5P-6185 
—  7T-2823  5P-6185 
—  7T-3064  5P-6185 
7T-3115, 312-6539  7T-3115, 312-6539  4C-6261 
7T-4007  7T-4006  5P-6185 
—  7T-5035  5P-6184 
—  7T-5646  4C-6261 
—  7U-3262  5P-6187 
—  7V-2150  5P-6190 
7V-2151  7V-2152  5P-6190 
—  7V-2154  5P-6190 
—  7V-4074  5P-6185 
—  7V-4075  5P-6185 
—  7V-4084  5P-6186 
8D-1948  8D-0526  5P-6183 
235-2642  8E-0367, 235-2643  — 
8E-1774  8E-1775  5P-6190 
—  8E-1873  4C-6261 
—  8E-2992  4C-6263 
—  8E-3679  5P-6190 
8E-4616  8E-4586  5P-6184 
8E-7087  8E-5910  5P-6190 
8E-9487  8E-9466  5P-6190 
—  8M-8161  5P-6190 
—  8M-8628  5P-6177 
9G-3542  8P-1719  5P-6185 
—  8P-1880  4C-6261 
—  8P-4455  — 
—  8P-4543  — 
—  8P-5653  — 
—  8P-6083  5P-6190 
—  8P-7351  5P-6190 
—  8P-7456  5P-6181 
101-7689  8P-8559  5P-6185 
8P-8843  8P-8844  5P-6190 
—  8R-8516  4C-6263 
—  8S-3497  5P-6182 
—  8S-3554  5P-6185 
—  8S-6259  5P-6182 
—  8S-6263  5P-6177 
—  8S-6370  5P-6190 
100-6769  8V-7320  5P-6182 
—  8W-1591  5P-6184 
8W-1592  8W-1592  5P-6177 
—  8Y-0803  5P-6180 
—  8Y-0806  5P-6182 
—  8Y-0808  5P-6180 
—  9C-1394  5P-6185 
—  9C-1395  5P-6185 
—  9C-3525  5P-6183 
—  9C-4080  5P-6185 
—  9C-7415  5P-6184 
—  9G-0401  5P-6177 
—  9G-0925  5P-6176 
—  9G-5844  5P-6184 
—  9G-9002  5P-6181 
—  9K-7915  5P-6184 
—  9K-7916  5P-6184 
—  9M-2062  4C-6263 
—  9M-2514  4C-6260 
—  9M-6844  5P-6177 
—  9P-0071  5P-6190 
9G-1930  9P-1250  5P-6190 
—  9P-9244  5P-6187 
—  9R-4315  5P-6181 
—  9S-5263  5P-6177 
—  9S-8147  5P-6180 
—  9S-9880  4C-6260 
9W-7704  9W-7703  5P-6181 
9W-7702  9W-7705  5P-6181 
—  034-8552  4C-6257 
—  038-2736  4C-6257 
—  068-2949  5P-6182 
—  068-4797  5P-6176 
—  068-9565  5P-6182 
—  108-5732  5P-6182 
—  108-5735  5P-6182 
—  108-6954  4C-6257 
108-8296  108-8297  5P-6178 
110-9311  110-9310  5P-6187 
—  112-0782  5P-6178 
—  112-5460  4C-6263 
112-4782, 163-1106, 162-9969  113-4633, 163-1105, 162-9967  5P-6190 
—  115-1326  5P-6178 
121-3173  121-3172  5P-6184 
124-9302  124-9301  4C-6263 
117-4465  125-8800  5P-6184 
—  134-3032  5P-6177 
134-4077  134-4077  4C-6261 
—  137-2417  4C-6261 
—  142-1280  5P-6187 
—  143-1736  — 
148-9319  148-9318  5P-6184 
153-1229  149-3973  4C-6263 
—  155-5602  5P-6177 
—  156-1150  5P-6177 
—  156-1151  5P-6178 
158-0424  158-0425  — 
—  160-1400  5P-6184 
—  171-6803  4C-6263 
193-4589  193-7146  5P-6184 
199-7967  199-7966  4C-6263 
203-2759  203-2760  5P-6184 
225-0086  224-9314  4C-6262 
—  250-3221  5P-6185 
255-0777  256-3657  — 
271-7121  271-7122  5P-6179 
271-8522  271-8522  5P-6179 
271-8523  271-8523  5P-6179 
279-2540  279-2547  — 
—  287-4002  4C-6742 
315-6193  322-7313  4C-6261 
122-6787  324-1357  4C-6257 
—  331-8520  5P-6180  
334-7506  334-7971  5P-6174 
348-7762  348-7761  None 
357-0596  357-0596  5P-6182 
366-5616  357-0597  5P-6182 
366-5615  357-0598  5P-6182 
358-3824  358-3825  4C-6261 
388-8448  362-7687  4C-6257 
—  364-4406  4C-6259 
365-1297  364-4407  4C-6259 
—  378-2791  5P-6181 
383-7979  383-8019  5P-6173  
260-3964  387-7687  5P-6184 
430-7997  394-9495  5P-6174 
441-9224  441-9225  5P-6185 
—  437-5514  4C-6261 
—  476-8753  — 
486-2947  486-2946  5P-6184 
483-1058  501-9091  5P-6184 
(1) Refer to Table 4 for the corresponding sleeve driver.

Wear Sleeve Installation



    Illustration 17g02319695
    Wear surface of seal with wear groove (3)

  1. Carefully inspect the shaft surface for seal wear. Wear groove (3) shows typical wear caused by a lip-type seal.


    Illustration 18g02323313
    Cleaning method that can be used on yokes, shafts, and flanges.

  2. Clean the wear surface thoroughly with a 180 grit or finer emery cloth. Use a file to remove any nicks or burrs (deep grooves or notches).


    Illustration 19g02323314
    Wear sleeve installation
    (3) Wear groove
    (8) Flange
    (9) Wear surface
    (10) Wear sleeve
    (11) Mark

  3. Hold wear sleeve (10) in the position shown in Illustration 19, so that the center of new wear surface (9) is over wear groove (3). Then, make a mark (11) that is even with the back of flange (8) on wear sleeve (10). If the flange (8) will be against a shoulder after the sleeve is installed, mark (11) is not needed. Refer to Step 8.

    Note: If there is more than one wear groove, make sure that all wear grooves will be covered an even amount.



    Illustration 20g02323335
    Shaft with wear groove
    (3) Wear groove

  4. If groove (3) is a deep groove, fill with a powdered metal epoxy and install the wear sleeve before the epoxy becomes hard. If the powdered metal is not needed, put Paint Primer on the area around groove (3). Put a small amount of 9S-3265 Compound on the area around groove (3) and inside of the new wear sleeve.


    Illustration 21g02323356
    Install wear sleeve
    (8) Flange
    (10) Wear sleeve
    (11) Mark

  5. Put wear sleeve (10) in position so flange (8) goes on first, as shown in Illustration 21. Be sure that the wear sleeve is kept straight as during installation. Use the correct sleeve driver and a press to install the wear sleeve in the correct position.


    Illustration 22g02323535
    Drive wear sleeve onto shaft with a press or a soft hammer.

  6. If a press is not available, use a soft hammer with the sleeve driver to install the wear sleeve, as shown in Illustration 22.


    Illustration 23g02323553
    Sleeve driver (6) with roller part (4)

  7. If a type (6) sleeve driver is used (refer to "Wear Sleeves and Wear Sleeve Drivers"), be sure to put the rolled (round) part (4) next to the sleeve.


    Illustration 24g02323555
    Shaft with chamfer
    (8) Flange
    (12) Chamfer

  8. If there is a chamfer (12) on the original wear surface for the seal, install the wear sleeve far enough so that the end of the wear sleeve is beyond the chamfer, as shown in Illustration 24. If flange (8) of the wear sleeve is against a shoulder, do not remove. If flange (8) is not against a shoulder, it must be removed. Refer to Step 9.


    Illustration 25g02324933
    Remove flange
    (8) Flange
    (13) Diagonal pliers
    (14) Pre-cut line

  9. If flange (8) of the wear sleeve is not against a shoulder, and must be removed, use diagonal pliers (13) to cut flange (8) up to pre-cut line (14).


    Illustration 26g02324934
    Flange removal
    (8) Flange
    (15) Pliers

  10. Use straight pliers (15) to bend and remove flange (8).

Metal Spray Method to Repair Seal Surfaces

Metal spray is an acceptable method of restoring a surface to the original size. Refer to section "Thermal Spray Procedure". Also, consult the manufacturer of the metal spray equipment for powder recommendations, machine settings, and application procedures. Each step in the procedure is critical in achieving the desired coating bond and surface texture.

Note: Sometimes, a yoke with seal lip damage can be reused without any salvage operations by installing the seal at a different position.

Acceptable surface texture on the shaft seal area must be within 0.25 mm and 0.50 mm (0.010 inch and 0.020 inch).

Plunge grinding is the grinding technique that should be used on the shaft sealing surface. This eliminates the possibility of a leak path that can be created if the traverse grinding method is used.



Illustration 27g03591670
Typical example of a Yoke.

Note: (C*) is when the other is not given.

Refer to Illustration 27 for dimensions listed in Table 6.

Table 6
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
1P-7522  1P-7521  36.60 ± 0.08 mm (1.44 ± 0.003 inch)  76.20 ± 0.03 mm (3.00± 0.001 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
1T-0364  1T-0364  38.10 ± 0.25 mm (1.50 ± 0.01 inch)  90.47 ± 0.08 mm (3.56 ± 0.003 inch)  1.49 ± 0.25 mm (0.06 ± 0.01 inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
1T-0365  1T-0365  38.10 ± 0.25 mm (1.50 ± 0.01 inch)  90.47 ± 0.08 mm (3.56 ± 0.003 inch)  1.49 ± 0.25 mm (0.06 ± 0.01 inch)  1.50 ± 0.5 mm (0.06 ± 0.02 inch) 
1T-1386  1T-1386  22.86 ± 0.25 mm (0.90 ± 0.0010 inch)  76.20 ± 0.03 mm (3.00± 0.001 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
1T-1565  1T-1565  41.15 ± 0.25 mm (1.62 ± 0.01 inch)  107.95 ± 0.13 mm (4.25 ± 0.005 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
2P-4392  2P-4392  29.46 ± 0.08 mm (1.16 ± 0.003 inch)  76.20 ± 0.03 mm (3.00± 0.001 inch)  2.40 ± 0.50 mm (0.09 ± 0.02 inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
2S-3180  2S-3179  35.00 ± 0.25 mm (1.38 ± 0.01 inch)  95.25 ± 0.05 mm (3.75 ± 0.002 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch)  0.80 ± 0.25 mm (0.03 ± 0.01 inch) 
2V-5418  2V-5418  50.80 ± 0.20 mm (2.00 ± 0.008 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.30 ± 0.25 mm (0.13 ± 0.01 inch) 
2V-5893  2V-5893  50.80 ± 0.50 mm (2.00 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.80 ± 0.050 mm (0.19 ± 0.002 inch)  4.80 ± 0.050 mm (0.19 ± 0.002 inch) 
4E-2402  4E-2402  63.50 ± 0.50 mm (2.50 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  4.04 mm (0.16 inch) 
4E-3194  4E-3194  63.50 ± 0.50 mm (2.50 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  4.04 mm (0.16 inch) 
4E-3751  4E-3751  59.7 ± 0.5 mm (2.35 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  6.4 ± 0.5 mm (0.26 ± 0.02 inch) 
5D-0534  5D-0534  34.52 ± 0.25 mm (1.36 ± 0.01 inch)  95.25 ± 0.05 mm (3.75 ± 0.002 inch)  2.10 ± 0.25 mm (0.08 ± 0.01 inch)  1.19 ± 0.25 mm (0.05 ± 0.01 inch) 
6P-2923  173-0713  30.23 ± 0.25 mm (1.19 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  5.30 ± 0.50 mm (0.21 ± 0.02 inch)  .80 ± 0.20 mm (0.03 ± 0.008 inch) 
6P-4232  8P-6189  29.46 ± 0.25 mm (1.16 ± 0.01 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  2.39 ± 0.25 mm (0.09 ± 0.01 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
6Y-1415  6Y-1415  33.00 ± 0.50 mm (1.30 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch) 
6Y-6636  6Y-6633  50.75 ± 0.25 mm (2.00 ± 0.010 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.30 ± 0.25 mm (0.13 ± 0.01 inch) 
6Y-8137  6Y-7138  35.00 ± 0.50 mm (1.38 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.05 ± 0.25 mm (0.12008 ± 0.00984 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
7G-1139  7G-1161  86.09 ± 0.13 mm (3.39 ± 0.005 inch)  142.888 ± 0.013 mm (5.6255 ± 0.0005 inch)  1.20 ± 0.30 mm (0.05 ± 0.01 inch)  3.50 mm (0.14 inch) 
7T-3115
312-6539 
7T-3115
312-6539 
44.00 ± 0.50 mm (1.73 ± 0.02 inch)  107.95 ± 0.13 mm (4.25 ± 0.005 inch)  1.70 ± 0.50 mm (0.07 ± 0.02 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
8E-4616  8E-4586  46.50 ± 0.08 mm (1.83 ± 0.003 inch)  76.20 ± 0.03 mm (3.00± 0.001 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.60 ± 0.50 mm (0.06 ± 0.02 inch) 
8E-7087
162-9968 
8E-5910
162-9966 
49.80 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  6.4 ± 0.5 mm (0.26 ± 0.02 inch) 
8P-5653  8P-5653  85.09 ± 0.13 mm (3.35 ± 0.005 inch)  136.54 ± 0.01 mm (5.38 ± 0.00039 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch)  3.05 mm (0.12 inch) 
8W-1592  8W-1592  64.3 ± 0.5 mm (2.53 ± 0.02 inch)  79.45 ± 0.05 mm (3.13 ± 0.002 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
108-6954  108-6954  41.50 ± 0.25 mm (1.63 ± 0.01 inch)  82.55 ± 0.08 mm (3.25 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  2.00 ± 0.5 mm (0.08 ± 0.02 inch) 
112-0782  112-0782  77.2 ± 0.5 mm (3.04 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  5.1 ± 0.5 mm (0.20 ± 0.02 inch)  4.00 ± 0.5 mm (0.16 ± 0.02 inch) 
112-5460  112-5460  50.80 ± 0.20 mm (2.00 ± 0.008 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.8 ± 0.5 mm (0.189 ± 0.02 inch)  — 
121-3173  121-3172  35.00 ± 0.25 mm (1.38 ± 0.01 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  2.50 ± 0.50 mm (0.01 ± 0.02 inch)  1.60 ± 0.40 mm (0.063 ± 0.02 inch) 
124-9302, 199-7967  124-9301, 199-7966  50.80 ± 0.50 mm (2.00 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.05 ± 0.25 mm (0.12 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
132-0347  132-0347  50.80 ± 0.50 mm (2.00 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  3.06 mm (0.12 inch) 
134-3032  134-3032  74.7 ± 0.5 mm (2.94 ± 0.02 inch)  101.6 ± 0.08 mm (4.00 ± 0.003 inch)  5.00 ± 0.5 mm (0.20 ± 0.02 inch)  .8 ± 0.5 mm (0.03 ± 0.02 inch) 
137-2417  137-2417  32.7 ± 0.5 mm (1.29 ± 0.02 inch)  107.95 ± 0.1 mm (4.25 ± 0.004 inch)  2.975 ± 0.1 mm (0.117 ± 0.004 inch)  1.6 ± 0.4 mm (0.063 ± 0.016 inch) 
153-1229  149-3973  50.80 ± 0.20 mm (2.00 ± 0.008 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.30 ± 0.25 mm (0.13 ± 0.01 inch) 
155-5602  155-5602  77.2 ± 0.5 mm (3.04 ± 0.02 inch)  76.2 ± 0.08 mm (3.00 ± 0.003 inch)  5.00 ± 0.5 mm (0.20 ± 0.02 inch)  4.00 ± 0.5 mm (0.16 ± 0.02 inch) 
156-1150  156-1150  88.8 ± 0.5 mm (3.50 ± 0.02 inch)  101.6 ± 0.08 mm (4.00 ± 0.003 inch)  5.00 ± 0.5 mm (0.20 ± 0.02 inch)  .8 ± 0.5 mm (0.03 ± 0.02 inch) 
156-1151  156-1151  77.2 ± 0.5 mm (3.04 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  5.1 ± 0.5 mm (0.20 ± 0.02 inch)  — 
171-6803  171-6803  60.8 ± 0.5 mm (2.3937 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  4.8 ± 0.5 mm (0.189 ± 0.02 inch)  — 
172-6103  171-3943  63.50 ± 0.50 mm (2.50 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  6.00 ± 0.50 mm (0.24 ± 0.02 inch) 
173-5850  173-5850  59.7 ± 0.5 mm (2.35 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  6.4 ± 0.5 mm (0.26 ± 0.02 inch) 
176-7289  176-7289  59.7 ± 0.5 mm (2.35 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  6.4 ± 0.5 mm (0.26 ± 0.02 inch) 
193-4589  193-7146  32.00 ± 0.76 mm (1.26 ± 0.03 inch)  92.96 ± 0.76 mm (3.66 ± 0.03 inch)  11.53 ± 0.25 mm (0.45 ± 0.01 inch)  1.60 ± 0.40 mm (0.063 ± 0.02 inch) 
203-2759  203-2760  58.90 ± 0.5 mm (2.32 ± 0.02 inch)  76.20 ± 0.06 mm (3.00 ± 0.002 inch)  6.4 ± 0.5 mm (0.25 ± 0.02 inch)  — 
203-2764  203-2765  46.5 ± 0.5 mm (1.83 ± 0.02 inch)  76.2 ± 0.06 mm (3.00± 0.002 inch)  6.4 ± 0.5 mm (0.25 ± 0.02 inch)  — 
225-0086  224-9314  33 ± 0.25 mm (1.30 ± 0.01 inch)  115.93 ± 0.03 mm (4.56 ± 0.001 inch)  2.29 mm (0.09 inch)  0.5 mm (0.02 inch) 
260-3964  387-7687  49.25 ± 0.25 mm (1.94 ± 0.01 inch)  76.20 ± 0.08 mm (3.00 ± 0.0032 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
271-7121  271-7122  52.7 ± 1.7 mm (2.07 ± 0.07 inch)  97.0 ± 0.08 mm (3.82 ± 0.003 inch)  2.03 ± 0.25 mm (0.08 ± 0.01 inch)  4.00 ± 0.5 mm (0.16 ± 0.02 inch) 
271-8522  271-8522  54.0 ± 0.5 mm (2.13 ± 0.02 inch)  92.07 ± 0.08 mm (3.62 ± 0.003 inch)  1.5 ± 0.25 mm (0.06 ± 0.01 inch)  0.5 mm (0.02 inch) 
271-8523  271-8523  58.4 ± 0.5 mm (2.30 ± 0.02 inch)  97.0 ± 0.08 mm (3.82 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  4.00 ± 0.5 mm (0.16 ± 0.02 inch) 
279-2540  279-2547  33.00 ± 0.25 mm (1.30 ± 0.01 inch)  115.93 ± 0.03 mm (4.56 ± 0.001 inch)  2.29 mm (0.09 inch)  0.5 mm (0.02 inch) 
334-7506  334-7971  15.0 ± 0.25 mm (0.59 ± 0.010 inch)  48.00 + 0.00 - 0.16 mm (1.890 + 0.00 - 0.006 inch)  2.00 ± 0.25 mm (0.079 ± 0.010 inch)  2.0 ± 0.25 mm (0.08 ± 0.010 inch) 
348-7762  348-7761  99.68 ± 0.13 mm (3.924 ± 0.005 inch)  142.888 ± 0.013 mm (5.6255 ± 0.0005 inch)  1.20 ± 0.30 mm (0.05 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
357-0596  357-0596  62.5 ± 0.5 mm (2.46 ± 0.02 inch)  69.85 ± 0.08 mm (2.75 ± 0.003 inch)  7.7 mm (0.30 inch)  — 
366-5615  357-0598  58.90 ± 0.5 mm (2.32 ± 0.02 inch)  69.85 ± 0.08 mm (2.75 ± 0.003 inch)  7.7 mm (0.30 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
366-5616  357-0597  58.90 ± 0.5 mm (2.32 ± 0.02 inch)  69.85 ± 0.08 mm (2.75 ± 0.003 inch)  7.7 mm (0.30 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
378-2791  378-2791  31.80 ± 0.50 mm (1.25 ± 0.02 inch)  66.68 mm (2.63 inch)  3.23 mm (0.13 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
—  9U-3668  —  76.2 ± 0.5 mm (3.00 ± 0.02 inch)  6.4 ± 0.5 mm (0.25 ± 0.02 inch)  — 
—  115-1326  49.30 ± 0.5 mm (1.9409 ± 0.0197 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  0.5 mm (0.02 inch) 
—  142-1736  33.00 ± 0.25 mm (1.30 ± 0.01 inch)  115.93 ± 0.03 mm (4.56 ± 0.001 inch)  2.29 mm (0.09 inch)  0.5 mm (0.02 inch) 
—  383-8942  50.0 ± 0.25 mm (1.97 ± 0.01 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  —  3.2 ± 0.5 mm (0.13 ± 0.02 inch) 


Illustration 28g03591684
Typical example of a Yoke.

Note: (C*) is when the other is not given.

Refer to Illustration 28 for dimensions listed in Table 7.

Table 7
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
7U-3262  7U-3262  39.50 ± 0.25 mm (1.55 ± 0.01 inch)  88.90 ± 0.08 mm (3.50 ± 0.003 inch)  1.50 mm (0.06 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
9C-4080  9C-4080  38 ± 0.5 mm (1.50 ± 0.02 inch)  79.38 ± 0.08 mm (3.125 ± 0.003 inch)  1.5 ± 1 mm (0.06 ± 0.04 inch)  3.0 ± 0.5 mm (0.12 ± 0.02 inch) 
142-1280  142-1280  34.19 ± 0.25 mm (1.346 ± 0.010 inch)  88.9 ± 0.08 mm (3.50 ± 0.003 inch)  3.0 ± 0.08 mm (0.118 ± 0.003 inch)  1.5 ± 0.25 mm (0.059 ± 0.010 inch) 


Illustration 29g03591695
Typical example of a Yoke.

Note: (C*) is when the other is not given.

Refer to Illustration 29 for dimensions listed in Table 8.

Table 8
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
1T-2006
158-0426 
1T-2006
158-0426 
31.80 ± 0.50 mm (1.25 ± 0.02 inch)  107.95 ± 0.13 mm (4.25 ± 0.01 inch)  3.00 ± 0.250 mm (0.12 ± 0.01 inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
9G-3542  8P-1719  36.00 ± 0.50 mm (1.42 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.0031 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.60 ± 0.20 mm (0.063 ± 0.008 inch) 
101-7689  8P-8559  41.00 ± 0.50 mm (1.61 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.0031 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch)  1.60 ± 0.20 mm (0.063 ± 0.008 inch) 
108-8296  108-8297  37.5 ± 0.5 mm (1.476 ± 0.02 inch)  55.029 ± 0.01 mm (2.1664 ± 0.0004 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  2.0 ± 0.5 mm (0.08 ± 0.02 inch) 
108-8854
194-2221 
108-8855
194-2220 
35.00 ± 0.50 mm (1.38 ± 0.02 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  3.05 ± 0.25 mm (0.12 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
117-4465  125-8800  36.00 ± 0.5 mm (1.42 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  0.5 mm (0.02 inch) 
122-6787  324-1357  15.00 ± 0.25 mm (0.59 ± 0.01 inch)  47.92 ± 0.02 mm 48.08 ± 0.05 mm (1.89 ± 0.0008 inch 1.89 ± 0.002 inch)  2.00 ± 0.25 mm (0.08 ± 0.01 inch)  2.00 ± 0.5 mm (0.08 ± 0.02 inch) 
219-8828  219-8828  21.00 +1.5 mm (0.83 + 0.06 inch)  65.00 - 0.074 mm (2.56 - 0.003 inch)  3.00 ± 0.01 mm (0.12 ± 0.0004 inch)  1.2 mm (0.05 inch) 
230-7160  230-7161  50.8 ± 0.5 mm (2.00 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.0031 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.60 ± 0.20 mm (0.063 ± 0.008 inch) 
255-0777  256-3657  32.0 ± 0.5 mm (1.26 ± 0.020 inch)  146.05 ± 0.1 mm (5.750 ± 0.004 inch)  4.00 ± 0.5 mm (0.157 ± 0.020 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
388-8448  362-7687  15 mm (0.59 inch)  47.92 ± 0.02 mm 48.08 ± 0.05 mm (1.89 ± 0.0008 inch 1.89 ± 0.002 inch)  2.00 mm (0.08 inch)  2.00 ± 0.5 mm (0.08 ± 0.02 inch) 
424-0873  424-0874  38.8 ± 0.5 mm (1.53 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.0031 inch)  —  — 
—  216-4464  21.00 +1.5 mm (0.83 + 0.06 inch)  65.00 - 0.074 mm (2.56 - 0.003 inch)  3.00 ± 0.01 mm (0.12 ± 0.0004 inch)  1.2 mm (0.05 inch) 


Illustration 30g03591703
Typical example of a Yoke.

Note: (C*) is when the other is not given.

Refer to Illustration 30 for dimensions listed in Table 9.

Table 9
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
1T-2000  1T-1999  22.60 ± 0.50 mm (0.89 ± 0.02 inch)  88.90 ± 0.08 mm (3.50 ± 0.003 inch)  1.55 ± 0.25 mm (0.06 ± 0.01inch)  1.50 ± 0.50 mm (0.06 ± 0.02 inch) 
1T-2032  1T-2030  29.20 ± 0.25 mm (1.15 ± 0.01 inch)  107.95 ± 0.13 mm (4.25 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  .80 ± 0.20 mm (0.032 ± 0.008 inch) 
2V-7170  2V-7170  38.10 ± 0.50 mm (1.50 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.25 mm (0.19 ± 0.01 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
3T-8305  3T-8304  —  72.0 ± 0.5 mm (2.83 ± 0.02 inch)  3.0 ± 0.5 mm (0.12 ± 0.02 inch)  3.0 ± 0.5 mm (0.12 ± 0.02 inch) 
6W-7385  6W-4759  38.10 ± 0.50 mm (1.50 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.25 mm (0.19 ± 0.01 inch)  0.80 ± 0.25 mm (0.03 ± 0.01 inch) 
6Y-6637  6Y-6631  40.70 ± 0.25 mm (1.60 ± 0.01 inch)  165.10 ± 0.15 mm (6.50 ± 0.006 inch)  5.00 ± 0.25 mm (0.20 ± 0.01 inch)  1.50 ± 0.25 mm (0.06 ± 0.01inch) 
6Y-6638  6Y-6630  38.50 ± 0.25 mm (1.52 ± 0.01 inch)  165.10 ± 0.15 mm (6.50 ± 0.006 inch)  —  1.50 ± 0.25 mm (0.06 ± 0.01inch) 
7V-2151  7V-2152  31.15 ± 0.25 mm (1.23 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  5.20 ± 0.50 mm (0.21 ± 0.02 inch)  .80 ± 0.20 mm (0.03 ± 0.008 inch) 
8E-0367
235-2642 
8E-0367
235-2642 
38.00 ± 0.25 mm (1.50 ± 0.010 inch)  107.95 ± 0.1 mm (4.25 ± 0.004 inch)  4.80 ± 0.50 mm (0.19 ± 0.02 inch)  4.04 ± 0.20 mm (0.16 ± 0.008 inch) 
8E-4615
173-0587 
4E-2384
171-3940 
49.66 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  5.00 ± 0.50 mm (0.20 ± 0.02 inch)  .80 ± 0.20 mm (0.03 ± 0.008 inch) 
8P-0514  1V-8565  44.50 ± 0.50 mm (1.75 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.25 mm (0.19 ± 0.01 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
8P-1880  8P-1880  41.10 ± 0.50 mm (1.62 ± 0.02 inch)  107.95 ± 0.10 mm (4.25 ± 0.004 inch)  2.80 ± 0.50 mm (0.11 ± 0.02 inch)  .80 ± 0.50 mm (0.03 ± 0.02 inch) 
8P-6083  8P-6083  34.00 ± 0.50 mm (1.34 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  3.00 ± 0.50 mm (0.11811 ± 0.01969 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
8S-6370  8S-6370  38.10 mm (1.50 inch)  101.60 ± 0.03 mm (4.00 ± 0.001 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.00 ± 0.08 mm (0.12 ± 0.003 inch) 
9P-0071  9P-0071  34.00 ± 0.50 mm (1.34 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.00 ± 0.250 mm (0.16 ± 0.01 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
9U-0346  9U-0346  49.66 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch) 
107-5610  6W-4281  41.5 ± 0.5 mm (1.634 ± 0.02 inch)  108.5 ± 0.5 mm (4.27 ± 0.02 inch)  6.65 ± 0.25 mm (0.26 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
107-5614
171-3942 
107-5614
171-3942 
51.46 ± 0.50 mm (2.03 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.00 ± 0.50 mm (0.16 ± 0.02 inch)  .80 ± 0.20 mm (0.03 ± 0.008 inch) 
107-6356  107-5613  30.23 ± 0.25 mm (1.19 ± 0.010 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
110-2141  110-2141  30.00 ± 0.50 mm (1.18 ± 0.02 inch)  107.95 ± 0.10 mm (4.250 ± 0.004 inch)  2.98 ± 0.02 mm (0.12 ± 0.0008 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
134-4077  134-4077  31.00 ± 0.50 mm (1.22 ± 0.02 inch)  107.95 ± 0.025 mm (4.25 ± 0.001 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  1.60 ± 0.40 mm (0.06 ± 0.02 inch) 
148-8889  149-0735  36.00 ± 0.50 mm (1.42 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  6.05 ± 0.50 mm (0.24 ± 0.02 inch)  — 
156-3640  156-3640  51.46 ± 0.50 mm (2.03 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.00 ± 0.50 mm (0.16 ± 0.02 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
158-0424  158-0425  29.20 ± 0.25 mm (1.15 ± 0.01 inch)  107.95 ± 0.13 mm (4.25 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  .80 ± 0.20 mm (0.032 ± 0.008 inch) 
171-3941  171-3941  49.66 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch) 
173-0714  173-0714  49.66 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch)  4.80 ± 0.050 mm (0.18898 ± 0.00197 inch) 
174-3405  174-3404  30.23 ± 0.25 mm (1.19 ± 0.010 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch)  3.00 ± 0.25 mm (0.12 ± 0.01 inch) 
178-6352  178-6352  49.66 ± 0.25 mm (1.96 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  5.00 ± 0.50 mm (0.20 ± 0.02 inch)  .80 ± 0.20 mm (0.03 ± 0.008 inch) 
253-5413  233-8102  51.0 ± 0.25 mm (2.01 ± 0.01 inch)  97.0 ± 0.08 mm (3.82 ± 0.003 inch)  3.5 ± 0.50 mm (0.14 ± 0.020 inch)  3.0 mm (0.12 inch) 
271-1573  7T-5646  41.10 ± 0.50 mm (1.62 ± 0.02 inch)  109.50 ± 0.50 mm (4.31 ± 0.02 inch)  2.80 ± 0.50 mm (0.11 ± 0.02 inch)  .80 ± 0.20 mm (0.032 ± 0.008 inch) 
358-3824  358-3825  29.20 ± 0.25 mm (1.15 ± 0.01 inch)  107.95 ± 0.13 mm (4.25 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch)  .80 ± 0.20 mm (0.032 ± 0.008 inch) 
308-6000  308-5846  33.06 ± 0.25 mm (1.301 ± 0.009 inch)  85.72 ± 0.08 mm (3.375 ± 0.003 inch)  3.0 ± 0.25 mm (0.118 ± 0.009 inch)  15° 
360-8791  365-3046  36.00 ± 0.50 mm (1.42 ± 0.02 inch)  76.20 ± 0.08 mm (3.00 ± 0.003 inch)  6.05 ± 0.50 mm (0.24 ± 0.02 inch)  — 
364-4406  364-4406  32 mm (1.26 inch)  90 mm (3.54 inch)  —  — 
365-1297  364-4407  32 mm (1.26 inch)  90 mm (3.54 inch)  —  — 
483-1058  501-9091  65.6 ± 1 mm (2.58 ± 0.04 inch)  76.2 ± 0.08 mm (3.00 ± 0.003 inch)  3.5 ± 0.08 mm (0.138 ± 0.003 inch)  3.0 mm (0.12 inch) Max 
486-2947  486-2946  36 ± 1 mm (1.417 ± 0.04 inch)  76.2 ± 0.08 mm (3.00 ± 0.003 inch)  3.5 ± 0.08 mm (0.138 ± 0.003 inch)  3.0 mm (0.12 inch) Max 
—  106-0721  38.50 ± 0.25 mm (1.516 ± 0.010 inch)  72.0 ± 0.13 mm (2.83 ± 0.005 inch)  4.0 ± 0.5 mm (0.16 ± 0.02 inch)  1.0 ± 0.2 mm (0.04 ± 0.008 inch) 
—  250-3220  38.0 ± 0.5 mm (1.50 ± 0.02 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  —  1.6 ± 0.4 mm (0.06 ± 0.02 inch) 
—  255-0777
447-7091 
25.5 ± 0.25 mm (1.00 ± 0.010 inch)  132.4 ± 0.05 mm (5.21 ± 0.002 inch)  1.50 ± 0.5 mm (0.060 ± 0.02 inch)  .8 ± 0.2 mm (0.03 ± 0.008 inch) 
—  287-4002  41.1 ± 0.5 mm (1.62 ± 0.02 inch)  107.95 ± 0.1 mm (4.250 ± 0.004 inch)  2.0 ± 0.5 mm (0.08 ± 0.02 inch)  .8 ± 0.2 mm (0.03 ± 0.008 inch) 
—  488-0171  28.0 mm (1.102 inch)  145.0 ± 0.1 mm (5.709 ± 0.004 inch)  —  20° 


Illustration 31g03591712
Typical example of a Yoke.

Refer to Illustration 31 for dimensions listed in Table 10.

Table 10
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
323-2169  3P-8143  31.75 ± 0.25 mm (1.25 ± 0.01 inch)  79.38 ± 0.08 mm (3.13 ± 0.003 inch)  —  1.52 ± 0.25 mm (0.06 ± 0.01 inch) 
3P-8142
6Y-8972
9G-8507 
3P-8142
6Y-8972
9G-8507 
21.82 ± 0.25 mm (0.86 ± 0.01 inch)  79.38 ± 0.08 mm (3.13 ± 0.003 inch)  —  1.50 ± 0.25 mm (0.06 ± 0.01 inch) 
148-9319  148-9318  21.5 ± 0.25 mm (0.85 ± 0.0010 inch)  76.2 ± 0.08 mm (3.0 ± 0.003 inch)  —  1.2 ± 0.3 mm (0.047 ± 0.012 inch) 
250-3221  250-3221  21.82 ± 0.25 mm (0.86 ± 0.01 inch)  79.38 ± 0.08 mm (3.13 ± 0.003 inch)  —  1.50 ± 0.25 mm (0.06 ± 0.01 inch) 
441-9224  441-9225  21.82 ± 0.25 mm (0.859 ± 0.010 inch)  79.38 ± 0.08 mm (3.125 ± 0.003 inch)  —  1.5 mm (0.059 inch) 


Illustration 32g03591856
Typical example of a Yoke.

Note: (C*) is when the other is not given.

Refer to Illustration 32 for dimensions listed in Table 11.

Table 11
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
3K-9917
7K-1261 
3K-9663
7K-1261 
19.00 ± 0.08 mm (0.75 ± 0.003 inch)  102.11 ± 0.03 mm (4.02 ± 0.001 inch)  3.05 ± 0.25 mm (0.12 ± 0.01 inch)  2.29 ± 0.51 mm (0.09 ± 0.02 inch) 
3T-8034  3T-8034  24 ± 0.25 mm (0.94 ± 0.01 inch)  101.6 ± 0.08 mm (4.00 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  2.00 ± 0.5 mm (0.08 ± 0.02 inch) 
6D-9818  6D-9819  19.81 ± 0.25 mm (0.78 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch) 
6I-8053  6I-8052  7.00 ± 0.25 mm (0.28 ± 0.01 inch)  75.70 ± 0.03 mm (3.00 ± 0.001 inch)  2.39 ± 0.25 mm (0.09 ± 0.01 inch)  3.00 ± 0.50 mm (0.12 ± 0.02 inch) 
6S-0335  6S-0286  17.53 ± 0.50 mm (0.69016 ± 0.01969 inch)  102.21 ± 0.13 mm (4.02401 ± 0.00512 inch)  3.00 ± 0.25 mm (0.11811 ± 0.00984 inch)  2.29 ± 0.51 mm (0.09016 ± 0.02008 inch) 
108-8297  108-8297  37.5 ± 0.5 mm (1.48 ± 0.02 inch)  69.85 ± 0.08 mm (2.75 ± 0.003 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch)  3.00 ± 0.5 mm (0.12 ± 0.02 inch) 
117-5793  117-5793  19.00 ± 0.25 mm (0.75 ± 0.01 inch)  111.13 ± 0.08 mm (4.38 ± 0.003 inch)  2.10 ± 0.25 mm (0.08 ± 0.01inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch) 
118-2109  118-2109  27.00 ± 0.25 mm (1.06 ± 0.01 inch)  127.00 ± 0.10 mm (5.00 ± 0.004 inch)  2.10 ± 0.04 mm (0.08 ± 0.002 inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch) 
131-8246  131-8247  21.00 ± 0.05 mm (0.83 ± 0.002 inch)  101.60 ± 0.05 mm (4.00 ± 0.002 inch)  1.50 ± 0.25 mm (0.06 ± 0.01 inch)  4.00 ± 0.25 mm (0.16 ± 0.01 inch) 
155-2077  155-2077  47.50 ± 0.50 mm (1.87± 0.02 inch)  107.95 ± 0.10 mm (4.25 ± 0.004 inch)  1.60 ± 0.40 mm (0.06± 0.02 inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch) 
329-3804  329-3804  47.50 ± 0.50 mm (1.87± 0.02 inch)  107.95 ± 0.10 mm (4.25 ± 0.004 inch)  1.60 ± 0.40 mm (0.06± 0.02 inch)  2.50 ± 0.50 mm (0.10 ± 0.02 inch) 


Illustration 33g03591862
Typical example of a Yoke.

Refer to Illustration 33 for dimensions listed in Table 12.

Table 12
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
110-9311  110-9310  39.00 ± 0.25 mm (1.54 ± 0.01 inch)  101.60 ± 0.08 mm (4.00 ± 0.003 inch)  2.00 ± 0.250 mm (0.07874 ± 0.00984 inch)  3.00 mm max (0.12 inch max) 


Illustration 34g06407539
Typical example of a Yoke.

Refer to Illustration 34 for dimensions listed in Table 13.

Table 13
Transmission and Differential Yokes 
Part Number  Yoke Number  Dimension A  Dimension B  Dimension C  Dimension D
Radius 
308-6005  308-5851  39 ± 0.25 mm (1.535 ± 0.009 inch)  85.72 ± 0.08 mm (3.374 ± 0.003 inch)  3.0 ± 0.25 mm (0.118 ± 0.009 inch)  0.5 mm (0.019 inch) Max 

Thermal Spray Procedure

Part Description

Table 14
Base Metal  Steel Forging 
Hardness  23-28 Rc 

Arc Spray Equipment and Procedure

Table 15
Arc Spray Equipment 
Maximum Surface Texture  6.1 µm (240.00 µinch) 
Reason for Spraying  Seal Wear 
Mating Part Contact Area & Material  Seal 
Arc Spray Equipment Type  SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU 
Wire  TAFA Alcro Wire Top Coat; TAFA 75B Bond Coat 
Finish Thickness  As Required 
Finishing Allowance  0.51 to 0.64 mm (0.020 to 0.025 inch) per side 
Spray Angle  70° to 90° 
Substrate Pre-Heat Temperature  66° C (150° F) Do not direct arc on area to be sprayed 
Substrate Temperature During Spraying Not to Exceed  148° C (300° F) 
Auxiliary Cooling  Filtered shop air 
Rotation/Traverse Device  Lathe 
Rotation Speed  92.0 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit blast 
Machining Method  Machine 
Equipment Required  Turn (Horizontal or Vertical) Lathe 
Recommended Cutting Tool  ISCAR DNMG 432 TF IC507 
Blast Media Recommendation  Pressure Type Only (Aluminum Oxide Grit) 
Grinding Equipment  Dunmore Tool Post Grinder 
Recommended Abrasive  Norton 32A 46-H8VBE 
Remarks  1) No lead on grinding
2) Roundness specification of 0.05 mm (0.002 inch) 

Table 16
Arc Spray  Procedure  Check List 
Clean Part  Degrease in hot Aluminum safe cleaner   
Undercut  If desired   
Chamfer  30°   
Remove Oxide  Use fiber flap brush or Clean/strip disc   
Clean Spray Area  Commercial degreaser   
Mask for Grit Blaster  Duct tape, metal shield, or rubber   
Grit Blast Equipment  Pressure type only   
Grit Type and Size  20 mesh aluminum oxide   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 to 150 mm (2.0 to 6.0 inch)   
Remove Blast Mask  Make sure that surface is clean   
Mask for Metal Spray  Antibond or Blue Layout Dye   
Metal Spray Equipment Type  Smart Arc by Oerlikon Metco  TAFA   
  Consumable (Bondcoat)  TAFA 75B  TAFA 75B   
  Clamp Pressure  275 kPa (40 psi)     
  Air Jets/Pressure  415 kPa (60 psi)  415 kPa (60 psi)   
  Arc Load Volts  30V  30V   
  Amps  125 Amps  150 Amps   
  Gun to Work Distance (Standoff)  128 mm (5.0 inch)  128 mm (5.0 inch)   
  Spray Rate/Bond Pass  0.038 mm (0.0015 inch)/pass  0.038 mm (0.0015 inch)/pass   
  Consumable (Topcoat)  TAFA Alcro  TAFA Alcro   
  Clamp Pressure  275 kPa (40 psi)     
  Air Jets/Pressure  415 kPa (60 psi)  415 kPa (60 psi)   
  Arc Load Volts  30V  29V   
  Amps  150 Amps  125 Amps   
  Gun to Work Distance (Standoff)  76.2 mm (3.00 inch)  76.2 mm (3.00 inch)   
  Spray Rate/Build Up  0.038 mm (0.0015 inch)/pass  0.038 mm (0.0015 inch)/pass   
  Rotation Speed of Part (RPM)  RPM varies depending on diameter (52 to 143 RPM)   
  Rotation Speed of Part  92 SMPM (300 SFPM)   
  Traverse Rate of Gun  11 SMPM (40 SFPM)   
Gun Fixturing Method  Machine mount or hand held   
Finishing Equipment  Lathe   
Part/Cutter Rotation Roughing  50 SMPM (150.00 SFPM)   
Part/Cutter Rotation Finishing  75 SMPM (250.00 SFPM)   
Coolant  Oil base synthetic - 40:1 ratio   
Traverse Speed  0.30 mm (0.012 inch)   
Depth of Rough Cut  0.51 mm (0.020 inch)   
Depth of Finish Cut  0.25 mm (0.010 inch)   
Additional Finish Method  Grind surface for no lead   

Flame Spray Equipment and Procedure

Table 17
Flame Spray Equipment 
Maximum Surface Texture  6.1 µm (240.00 µinch) 
Reason for Spraying  Seal Wear 
Mating Part Contact Area & Material  Seal 
Oerlikon Metco Equipment Type  6P-II by Oerlikon Metco 
Metco Material  Metco 453 
Metco Sealer 
Finish Thickness  As Required 
Finishing Allowance  0.51 to 0.64 mm (0.020 to 0.025 inch) per side 
Spray Angle  70° to 90° 
Substrate Pre-Heat Temperature  66° C (150° F) Do not direct flame on area to be sprayed 
Substrate Temperature During Spraying Not to Exceed  148° C (300° F) 
Auxiliary Cooling  If desired 
Rotation/Traverse Device  Lathe 
Rotation/Traverse Speed  92.0 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit Blast 
Finishing Method  Machine 
Machining Equipment Type  Lathe 
Recommended Cutter Grade  C-2, 883 Carboloy or equivalent 
Remarks  1) No lead on grinding
2) Roundness specification of 0.05 mm (0.002 inch) 

Table 18
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  To "tru-up" surface   
Chamfer  30°   
Remove Oxide  Use fiber flap brush or Clean/strip disc   
Clean Spray Area  Metco cleaning solvent or equivalent   
Mask for Grit Blast  Duct Tape   
Grit Blast Equipment  Pressure   
Grit Type and Size  25 to 40 steel angular grit   
Blast Air Pressure  620 kPa (90.0 psi)   
Blast Nozzle to Work Distance  50 mm (2.0 inch)   
Remove Blast Mask  Make sure that surface is clean   
Mask for Metal Spray  Metco Antibond   
Metal Spray Equipment Type  6P-II Hand Held Thermo Spray System by Oerlikon Metco   
Auxiliary Cooling  If desired   
Nozzle  6P-C7A-K "K" Nozzle   
Air Capacity/Pressure  6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)   
Oxygen Pressure  210 kPa (30.0 psi)   
Oxygen Flow  1190 L/h (42.0 cfh)   
Fuel Gas Pressure  100 kPa (15.0 psi)   
Fuel Gas Flow  1415 L/h (50.0 cfh)   
Carrier Gas Pressure  380 kPa (55.0 psi)   
Carrier Gas Flow  1050 L/h (37.0 cfh)   
Spray Rate/Build Up  5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per min   
Gun to Work Distance  230 mm (9.0 inch)   
Rotation Speed of Part (RPM)  RPM varies depending on diameter (70 - 143 RPM)   
Rotation Speed of Part (SFPM)  92 SMPM (300.00 SFPM)   
Traverse Rate of Gun (SFPM)  15.0 SMPM (50.00 SFPM)   
Gun Fixturing Method  Machine mount   
Top Coat/Thickness  0.10 to 0.15 mm (0.004 to 0.006 inch) per pass   
Finishing Equipment  Lathe   
Part/Cutter Rotation (SFPM)  92.0 SMPM (300.00 SFPM)   
Traverse Speed  0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution   
Depth of Rough Cut  0.38 to 0.51 mm (0.015 to 0.020 inch) per side   
Depth of Finish Cut  0.25 to 0.38 mm (0.010 to 0.015 inch) per side   
Additional Finish Method  Emery cloth for desired finish, no lead   

Crack Detection Methods


NOTICE

Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.


There are five major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), Dry / Wet Magnetic Particle Testing (MPT), and Ultrasonic Testing (UT).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, Dry/ Wet MPT, and UT are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 19 for advantages and disadvantages and Table 20 for standards and requirements for these NDT methods.

Table 19
Crack Detection Methods Advantages vs. Disadvantages 
Detection Method  Advantages  Disadvantages 
Visual Surface Inspection (VT)  - Least Expensive
- Detects most damaging defects.
- Immediate Results
- Minimum part preparation 
- Limited to surface-only defects.
- Requires inspectors to have broad knowledge of welding and fabrication in addition to Non-Destructive Testing (NDT). 
Liquid Penetrant Testing (PT)  - Inexpensive
- Minimal Training
- Portable
- Works on nonmagnetic material. 
- Least Sensitive
- Detects surface cracks only.
- Rough or porous surfaces interfere with test 
Dry Magnetic Particle (MPT)  - Portable
- Fast/Immediate Results
- Detects surface and subsurface discontinuities 
- Works on magnetic material only.
- Less sensitive than Wet Magnetic Particle Testing (MPT). 
Wet Magnetic Particle (MPT)  - More sensitive than Liquid Penetrant Testing (PT).
- Detects subsurface as much as 0.13 mm (0.005 inch)
- Requires power for light.
- Works on magnetic material only.
- Liquid composition and agitation must be monitored. 
Ultrasonic Testing (UT)  - Most Sensitive
- Detects deep material defects.
- Immediate Results
- Wide range of materials and thickness can be inspected 
- Most Expensive
- Requires operator training and certification.
- Surface must be accessible to probe 

Table 20
Applicable Crack Detection Standards 
Detection Method  Standard  Acceptance
Criteria 
Minimum
Required
Personnel
Qualifications 
Visual Surface Inspection (VT)  EN-ISO 5817
AWS D1.1 
EN-ISO 5817 - Level B
AWS D1.1 - Table 6.1 
EN-ISO 9712
ANSI-ASNT SNT-TC-1A 
Liquid Penetrant Testing (PT)  EN-ISO 3452
ASTM E165 
EN-ISO 23277
AWS - D1.1 
EN-ISO 9712
ANSI-ASNT SNT-TC-1A 
Magnetic Particle Testing (MPT)  EN-ISO 17638
ASTM E709 
EN-ISO 23278 - Level 1
AWS D1.1 - Table 6.1 
EN-ISO 9712
ANSI-ASNT SNT-TC-1A 
Ultrasonic Testing (UT)  EN-ISO 17640 - Level B
AWS D1.1 
EN-ISO 11666 Technique 2 - Level 2
AWS D1.1 - Class A - Table 6.3 
EN-ISO 9712
ANSI-ASNT SNT-TC-1A 

Visual Surface Inspection (VT)



Illustration 35g06124166
Example of Visual Surface Inspection (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror

Refer to Tooling and Equipment Table 3 for part numbers.

Components and welds that are to be tested using PT, MPT, or UT shall first be subject to a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 35. Personnel performing VT shall either be trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. Personnel performing VT shall take routine eye exams.

Liquid Penetrant Testing (PT)

------ WARNING! ------

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do the job.

Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.


Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

  • Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

  • Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

  • Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.

  • Wire Brush: Removes dirt and paint.

  • Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure



    Illustration 36g06103795
    Typical example of pre-cleaning the testing area.

  1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.


    Illustration 37g06103803
    Typical example of applying penetrating oil to areas to be tested.

  2. Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.


    Illustration 38g06103816
    Typical example of removing penetrating oil with a cloth.

  3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.


    Illustration 39g06103820
    Typical example of applying the developer.

  4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately 203 - 305 mm (8.0 - 12.0 inch) away from the testing area. Apply an even, thin layer of developer over the testing area. A few thin layers are a better application method than one thick layer.


    Illustration 40g06084042
    Typical example of cracks found during Liquid Penetrant Testing (PT).

  5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 40. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MPT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.



Illustration 41g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke
(C) Dry Powder Bulb

  1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

  2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

  3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

  4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

  5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

  6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

  1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

  2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

  3. Simultaneously apply the dry powder using the dry powder blower.

  4. Remove excess powder by lightly blowing away the dry particles.

  5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

  6. Observe particles and note if any clusters of particles appear revealing an indication.

  7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MPT)

Materials and Equipment

Refer to Tooling and Equipment Table "Tooling and Equipment" for part numbers.



Illustration 42g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp


Illustration 43g06003178
Pear Shaped Centrifuge Tube

  1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

  2. Concentration:

    1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

    2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions, refer to Illustration 43. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

    3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

    4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 5 mm2/s (5 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

    5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 5 mm2/s (5 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

  3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

  1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

  2. Apply the magnetic field using the yoke against the surface in the area to be inspected.


    Illustration 44g03536210
    Yoke applied the area to be inspected.

  3. For case hardened and ground surfaces:

    • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 44 for an example of yoke placement.

  4. Visually inspect for indications of discontinuities using the proper illumination.

  5. Record the size and shape of any discontinuities found.

Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician. Refer to Table 20 for crack detection standards.

Refer to Tooling and Equipment Table 3 for part numbers.

  1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

  2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

    1. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect from the back surface of the material to project the thickness of the material.

    2. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.

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