Single Reduction Hydraulic Differential Lock Carriers (HDL ... · and Notes Service Notes WARNING A...

Single Reduction HydraulicDifferential Lock Carriers (HDL)Nez-De-Pont Simple avec un blocagedifferentiel Hydraulique (HDL)

Models / MòdelesRS-145 Carriers

Maintenance Manual 5.4 Issued 10-06Manuel de maintenance 5.4 Edité Octobre 06

Before You BeginThis maintenance manual describes the correct service and repair procedures for all AxleTech singlereduction carriers equipped with the hydraulic differ-ential lock (HDL) feature. The information containedin this manual was current at time of printing and issubject to change without notice or liability.

You must follow your company procedures when youservice or repair equipment or components. Youmust understand all procedures and instructionsbefore you begin to work on a unit. Some proceduresrequire the use of special tools for safe and correctservice. Failure to use special tools when requiredcan cause serious personal injury to service person-nel, as well as damage equipment and components.

AxleTech International uses the following notations to warn the user of possible safety problems and toprovide information that will prevent damage toequipment and components.

Safety Alerts, Torque Symbol and Notes

Service Notes

WARNING A Warning alerts you to aninstruction or procedure thatyou must follow exactly toavoid serious personalinjury.

CAUTION A Caution alerts you to an instruction or procedurethat you must follow exactly to avoid damage to components.

The torque symbol alertsyou to tighten fasteners to a specified torque value.

NOTE: A Note provides informationor suggestions that help you correctly service a component.

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The instructions contained in this Field MaintenanceManual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair and replacement of the AxleTechproduct described herein. Installation, maintenanceand replacement of such products require a highdegree of skill and experience. The consequences of improper installation, maintenance or replacement(including the use of inferior or substandard components) are grave and can result in product failure and resulting loss of control of the vehicle,possible injury to or death of persons and/or possible

future or additional axle damage. AxleTech does notauthorize anyone other than highly skilled and experienced individuals to attempt to utilize theinstructions contained in this Manual for the installation, maintenance or replacement of the product described herein, and AxleTech shall haveno liability of any kind for damages arising out of (or in connection with) any other use of the information contained in this Manual.

Additional PublicationsFor AxleTech service manuals, please contact:1-877-877-9717 and 248-816-5401 or visit our website at www.axletech.com.

How To OrderOrder items from AxleTech International.

Phone orders are also accepted by calling AxleTechInternational’s Customer Service Center at 877-547-3907 or send a fax to 866-547-3987.

Exploded ViewsSingle Reduction Carrier Assembly with Hydraulic Differential Lock (HDL) Feature......................................2Single Reduction Carrier with Standard Differential for Comparison to HDL Differential Feature: For Reference Only.........................................................................................................................................4

Section 1: IntroductionIdentification ....................................................................................................................................................5Single Reduction Carriers With Hydraulic Differential Lock (HDL) Feature....................................................5Carrier With And Without Trunnion Feature Comparison ...............................................................................6

Section 2: Removal & DisassemblyHydraulic Differential Operation Overview ......................................................................................................7Carrier Disassembly From The Vehicle Preliminary Preparation....................................................................7Axle Setup for HDL Carrier Disassembly........................................................................................................8Trunnion Design HDL Carrier Assembly .........................................................................................................8Standard HDL Carrier Assembly .....................................................................................................................8Carrier Disassembly Procedure ......................................................................................................................8HDL Differential Cross Section .....................................................................................................................10HDL Differential Disassembly........................................................................................................................11HDL Carrier Input Pinion and Bearing Cage.................................................................................................12Drive Pinion and Bearing Cage.....................................................................................................................13

Section 3: Prepare Parts for AssemblyClean Rough Parts........................................................................................................................................16Clean Ground and Polished Parts ................................................................................................................16Clean and Inspect Yokes ..............................................................................................................................16Dry Parts After Cleaning ...............................................................................................................................17Preventing Corrosion on Cleaned Parts .......................................................................................................17Inspect Parts .................................................................................................................................................17Tapered Bearing............................................................................................................................................17Pinions And Gears ........................................................................................................................................18Main Differential Assembly............................................................................................................................18Axle Shafts ....................................................................................................................................................18Hydraulic Differential Components................................................................................................................19Hydraulic Actuation Components ..................................................................................................................19Repair or Replace Parts................................................................................................................................20Fasteners ......................................................................................................................................................20Welding Repair..............................................................................................................................................20Silicon Gasket Material .................................................................................................................................20Gear Sets ......................................................................................................................................................21Gear Set Tooth Combination Number...........................................................................................................21Gear Set Match Number ...............................................................................................................................21Pinion Cone Variation Number......................................................................................................................21Carrier Assembly...........................................................................................................................................21Shim Table.....................................................................................................................................................22Thread Lockers, Adhesives, Sealants Table .................................................................................................22

Table of Contents

Section 4: AssemblyDrive Pinion, Bearings And Bearing Cage ....................................................................................................23One-Piece Spigot Bearing On The Drive Pinion With Snap-Ring ................................................................23Drive Pinion Assembly ..................................................................................................................................24Adjustment (Pinion Bearing Preload)............................................................................................................24Seal Installation.............................................................................................................................................25Input Bearing Cage Less-Trunnion Option ...................................................................................................25Input Bearing Cage-With Trunnion................................................................................................................26Yoke ..............................................................................................................................................................26Shim Pack Thickness For A New Drive Pinion .............................................................................................26Installation (Drive Pinion, Bearing Cage And Shim Pack Into The Carrier)..................................................28Assembly (Main Differential And Ring Gear Assembly of HDL Differential) .................................................29HDL Discs, Diaphragm Lever, Diff Case.......................................................................................................31HDL Discs - Initial Selection Of Shim Pack For Preload ..............................................................................31HDL Discs - Final Assembly..........................................................................................................................32HDL Piston ....................................................................................................................................................33Installation (Differential And Ring Gear Assembly Into Carrier) ....................................................................33Adjust Differential Bearing Preload ...............................................................................................................34Check Ring Gear Runout..............................................................................................................................35Ring Gear Backlash Adjustment ...................................................................................................................35Check Gear Set Tooth Contact Patterns (Backlash).....................................................................................37HDL Inlet Port................................................................................................................................................40Install And Adjust The Thrust Screw .............................................................................................................40Hydraulic Differential Lock (HDL) Actuation Function and Leak Test ...........................................................41

Section 5: LubricationBreather.........................................................................................................................................................42Seals .............................................................................................................................................................42Oil Level ........................................................................................................................................................42Approved Oil Listings ....................................................................................................................................42Approved Grease ..........................................................................................................................................42Hydraulic Differential Lock Oils .....................................................................................................................42Lubricant Specification Table: Viscosity and to Outside Temperature Chart ................................................43

Section 6: TorqueTorque Values For Fasteners........................................................................................................................44Torque Table..................................................................................................................................................45

Section 7: Adjustments and SpecificationsDrive Pinion Bearings — Preload .................................................................................................................46Drive Pinion — Depth in Carrier ...................................................................................................................46Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled)..........................................................................46Main Differential Bearings Preload ..............................................................................................................46Main Hydraulic Differential Lock Gears — Rotating Resistance ..................................................................46Ring Gear — Backlash .................................................................................................................................46Ring Gear — Runout ....................................................................................................................................46

Section 8: Special ToolsHow To Make A Flange Bar ..........................................................................................................................47Unitized Pinion Seals And Seal Drivers ........................................................................................................47Inspection Tool ..............................................................................................................................................48Unitized Pinion Seals And Seal Drivers ........................................................................................................48Center Assembly Stand.................................................................................................................................49

Table of Contents

Single Reduction Carrier Assembly with Hydraulic Differential Lock (HDL) Feature

Standard BearingCage Does NotAccept TrunnionBracket

Different Bearing CageShown with OscillatingTrunnion Mount Bracket

1615

1358

5960

61

62

12

8

1615 14

12

8

18

17

18

17

5

5

5554

52

53

1

51

5657

3

3

2221

24

24

25

34

2349

48

3550

20

28

4647

25

2627

31

3629

3037

45

34 35

44 4343

4240

4139

38

33

32

11

102

9

6

4

7

19

Exploded View

- 2 -

Item Description

1 CARRIER & CAP ASSY

2 SHIM PACK

3 PINION CAGE

4 BEARING CUP

5 BEARING CUP

6 BEARING CONE

7 BEARING SPACER

8 BEARING CONE

9 DRIVE PINION

10 SPIGOT BEARING

11 SNAP RING

12 OIL SEAL ASSEMBLY

13 YOKE

14 YOKE & DEFLECTOR ASSEMBLY

15 HARDENED WASHER

16 LOCK NUT

17 HARDENED WASHER

18 CAPSCREW

19 DIFFERENTIAL SPIDER

20 FLANGE HALF DIFF CASE

21 THRUST WASHER

22 DIFF PINION

23 PLAIN HALF DIFF CASE

24 SIDE GEAR

25 THRUST WASHER

26 STATIONARY DISC

27 FRICTION DISC

28 FRICTION DISC DRIVER

29 SHIM

30 SHIM

31 SHIM

Item Description

32 COVER HALF DIFF CASE

33 THRUST WASHER

34 BEARING CONE

35 BEARING CUP

36 PRESSURE PLATE

37 DIAPHRAGM LEVER

38 BRG ADJ RING

39 PISTON HOUSING

40 PISTON

41 D-RING SEAL

42 D-RING SEAL

43 THRUST WASHER

44 THRUST BEARING

45 ACTUATOR

46 RING GEAR

47 SOCKET HEAD CAPSCREW

48 HARDENED WASHER

49 CAPSCREW

50 BRG ADJUST RING

51 SCREW SPECIAL

52 INLET PORT

53 O-RING

54 HARDENED WASHER


56 THRUST SCREW

57 LOCK NUT

58 TRUNNION BRACKET

59 THRUST WASHER

60 SEAL ASSEMBLY

61 BUSHING

62 SEAL ASSEMBLY

Exploded View

- 3 -

Item Description

1 LOCK NUT

2 HARDENED WASHER

3 YOKE & DEFLECTOR ASSY

4 OIL SEAL ASSEMBLY

5 BEARING CONE

6 BEARING CUP

7 CAPSCREW

8 SPACER

9 HARDENED WASHER

10 PINION CAGE

11 BEARING CUP

12 BEARING CONE

13 SHIM PACK

14 DRIVE PINION

15 SPIGOT BEARING

16 SNAP RING

17 CARRIER & CAP ASSY

18 LOCK NUT

Item Description

19 THRUST SCREW

20 SCREW SPECIAL

21 BRG ADJUST RING

22 BEARING CUP

23 BEARING CONE

24 LOCK NUT

25 HARDENED WASHER

26 COVER HALF DIFF CASE

27 THRUST WASHER

28 SIDE GEAR

29 THRUST WASHER

30 DIFF PINION

31 DIFFERENTIAL SPIDER

32 RING GEAR


34 PLAIN HALF DIFF CASE

35 SCREW SPECIAL

Exploded View

Single Reduction Carrier with Standard Differential for Comparison toHDL Differential Feature: For Reference Only

3

1

2

6

8

11

12

16

17

21

22

23

359

342728

3332

31

30

29

28

27

26

25

24

23

2221

45

7

9

10

14

15

18

19

20

13

- 4 -

IdentificationSingle Reduction Carriers WithHydraulic Differential Lock (HDL)FeatureAxleTech single reduction carriers with hydraulic differential lock design (HDL) have the same type ofgears and bearings as carriers without the HDLfeature. Figure 1.1. The hydraulic differential lock isoperated by a hydraulic actuation pressure that hasits hydraulic actuation connection to the carrier shellassembly.

• When the differential lock is activated, the hydraulicpiston activates a lever force that compresses thefriction disc stack along the driver splines and thefriction disc stack applies the locking feature.

• When the hydraulic pressure is released, the frictiondisc stack is returned to the “non-apply” position asthe lever relaxes to eliminate friction drag.

• When the carrier operates with the hydraulic differential in the “locked” position, there is Nodifferential action between the wheels.

• When the carrier operates in the “non-pressurized”condition, there Is normal differential action betweenthe wheels.

An exploded view of Single Reduction CarrierAssembly With Hydraulic Differential Lock (HDL)Feature is shown on page 2. For Reference Only onpage 4, an exploded view of Single Reduction Carrierwith a Standard Differential is shown for comparison purposes to the carrier with the HDL DifferentialFeature. If you are working on a Single ReductionCarrier with a Standard Differential, refer toMaintenance Manual 5A.

The hydraulic differential lock assembly is currentlyavailable in both the standard single reduction carrierconfiguration and in the trunnion mount (oscillatingaxle) version of this same capacity carrier. The trunnioncarrier’s configuration has a trunnion bracket mountedon the different bearing cage with shared common internal components. Once the trunnion componentsare removed, the trunnion configuration carrier is serviced same as a non-trunnion carrier.

Hydraulic Inlet Port

DisengagedPiston

Position

EngagedPiston

Position

STANDARD CARRIER WITHHYDRAULIC DIFFERENTIALLOCK (HDL)

Figure 1.1

Section 1Introduction

- 5 -

Typical Carrier ModelDesignation Examples:

Trunnion Carrier - B13200V2076557Non-Trunnion Carrier - B13200L2092557

Carrier Tag

MODEL

CUST No.

SERIAL No.

RATIO DATE

Figure 1.3 IDENTIFICATIONTAG LOCATION

TRUNNION MOUNT CARRIERSTANDARD CARRIER

PINION BEARINGCAGE

CARRIER WITH AND WITHOUT TRUNNIONFEATURE COMPARISON

Figure 1.2

Carrier With And Without TrunnionFeature ComparisonThis model single reduction carrier is available witheither the standard carrier input bearing cage asshown on the left or with a different input bearingcage for the trunnion feature option as shown on theright view. Servicing of these two carrier options areidentical except where noted in this service manual.

To determine the exact carrier model specification,refer to the identification tag fastened to the carrierhousing. Figure 1.3.

Section 1Introduction

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WARNINGTo prevent serious eye injury, always wear safeeye protection when you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block thewheels to prevent the vehicle from moving.Support the vehicle with safety stands. Do notwork under a vehicle supported only by jacks.Jacks can slip and fall over. Serious personalinjury can result.

Use a brass or leather mallet for assembly anddisassembly procedures. do not hit steel partswith a steel hammer. Pieces of a part can breakoff and cause serious personal injury.

Hydraulic Differential Operation OverviewThe AxleTech single reduction carrier is equipped witha driver controlled hydraulically actuated main differ-ential lock (HDL) assembly. Once engaged, thehydraulic pressure applies through hydraulic pistonand lever assembly to compress a friction disk stackto lock the differential assembly. This effectively locksthe axle shafts together to remove any differentialaction until the hydraulic pressure is disengaged.Figure 2.1.

NOTE: The AxleTech carrier models equipped withhydraulic driver-controlled differential lock are manufactured in metric dimensions and sizes. Whenthese carriers are serviced, it is important to use thecorrect metric size tools on the fasteners. Refer to“Torque Table” in Section 6.

! Carrier Disassembly From TheVehicle Preliminary PreparationDisassembly From Vehicle:NOTE: Always follow the OEM recommended procedures for component removal from the vehicle.Listed below are our suggested guide comments forsafe removal and servicing of the axle and carriercomponents only.

WARNINGTo prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block thewheels to prevent the vehicle from moving.Support the vehicle with safety stands. Do notwork under a vehicle supported only by jacks.Jacks can slip and fall over. Serious personalinjury and damage to components can result.OEM service instructions should be followedwhen servicing these components under the vehicle.

NOTE: Any pre-cleaning on vehicle to removedirt/grease or corrosive material should be per vehiclemanufacturer recommendations. Care should betaken to cover the axle breather to limit additionalcontamination during pre-cleaning process.

1. Remove the magnetic oil drain plugs from the axlehousing bowl (1.06"-12) and each axle housingflange to drain the lubricant into a suitable contain-er. Note amount of metal on the magnetic drainplug and clean drain plug.

2. Remove and plug the hydraulic differential actua-tion line and the connection to the axle with integralwet brakes by following the OEM vehicle manufac-tures instructions to close hydraulic valves andplug lines and safe draining of fluids as required.Also disconnect any supplement greasing linesshould the trunnion carrier design require servicingper OEM vehicle manufacturers recommendation.

3. Disconnect the vehicle propshaft from the axleinput yoke per vehicle manufacturer recommenda-tions. If carrier being serviced is of trunnion design,please follow the servicing instructions in the sepa-rate axle manual to provide for correct and safeservicing recommendations. Care should be takenso personal injury does not occur.

WARNINGTake care when using lifting devices. When you use a lifting strap, inspect the strap for damage before you use it. Do not use a liftingstrap to shock load or drop load a component.Serious personal injury and damage to components can result.

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Figure 2.1

FLANGE HALF DIFF CASE

FRICTION DISCS &STATIONARY DISCS

FRICTIONDISC DRIVER

THRUST WASHER

DIAPHRAGMLEVER

PRESSUREPLATE

SHIM

COVER HALFDIFF CASE

THRUST WASHER

BEARINGCONE

Section 2Removal & Disassembly

- 7 -

4. Support the axle assembly for safe removal fromthe vehicle chassis frame.

5. Remove the axle assembly from the vehicle pervehicle manufacturer recommended proceduresand place on adequate safe axle stand or workbench to prepare for disassembly.

Axle Setup For HDL CarrierDisassembly

Trunnion Design HDL CarrierAssembly

CAUTIONIf axle being removed has the trunnion feature,Caution to note the trunnion bracket assembly onthe carrier input is loose on the axle assembly. Atemporary strap to secure the trunnion bracket tothe axle assembly during axle removal from thevehicle is recommended so personal injury andcomponent damage is protected.

1. To remove the carrier assembly from an axle withthe trunnion feature, refer to the correct axle man-ual for safe and recommended procedure toremove the individual trunnion components prioractual carrier removal. Once the trunnion feature isremoved, the recommended procedure is the sameas for the Carrier with HDL, less the trunnion.

Standard HDL Carrier Assembly 1. Remove the planetary wheel ends/wet brakes, if so

equipped, and axle shafts per the recommendedprocedure in axle manual that is provided for axlebeing serviced.

2. Attach an approved lifting device ,after carefullyinspecting the lifting straps. Figure 2.2.

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NOTE: These capscrews have high strength threadcompound applied during original production assembly.

3. Remove the metric capscrews (M16X2) and wash-ers that retain the carrier into the axle housing andplace the carrier safely and secure in a carrierstand or on a work bench so the carrier assemblywill not fall and cause personal injury or componentdamage. A typical carrier stand design is shown inthe tools section of this manual, see Section 7.

Note: The trunnion and standard carrier assemblieshave different quantity of metric capscrews and washers in this carrier to axle housing joint.

Note: A liquid gasket has been applied to the carrier to axle housing joint during original production assembly.

WARNINGUse a rawhide or brass mallet for disassembly andassembly procedures. Do not hit steel parts with asteel hammer. Pieces of a part can break off andcause serious injury. Use of safety glasses is alwaysrecommended when servicing the axle components.

Carrier Disassembly ProcedureShould the carrier upon inspection require disassem-bly, please use the following steps after the carrier issecurely retained for safe disassembly so no personal injury can occur. A carrier stand that will permit the carrier assembly to rotate is recommendedfor teardown and assembly with access to both topand bottom areas of the assembly. Refer to CenterAssembly stand in Special Tools Section 7.

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THRUST SCREW

AND JAM NUT

Figure 2.2


- 8 -

NOTE:Before working on the differential carrier,inspect the hypoid gear set for damage. If inspectionshows no damage, the same gear set can be usedagain. Measure the backlash of the gear set and run-out at the ring gear back surface. Make a record ofthe measurements. Figure 2.3 and 2.4.Refer to Section 4.

1. Loosen the jam nut on the thrust screw. Figure 2.5.

2. Remove the thrust screw and jam nut from the differential carrier. Figure 2.5.

NOTE: These (2) capscrews had Loctite 242 orequivalent, applied during original production assembly. Figure 2.6.

3. Remove the hydraulic inlet for the HDL by removingthe (2) M8 socket head capscrews and washers.

NOTE: Loctite 5699 or similar has been applied to theinlet port surface to seal this assembly during originalproduction assembly. The inlet port also locks the car-rier differential bearing adjusting ring.

DIAL

INDICATOR

1002991a

Figure 2.3

THRUST SCREW

AND JAM NUT

Figure 2.5

Rotate ring gear.

DIAL INDICATOR

1003084c

Figure 2.4


- 9 -

4. Carefully remove the HDL inlet port assemblywhich includes the inlet port and O-Ring and setaside for later inspection and reassembly.

5. Rotate the differential carrier in the repair standuntil the ring gear is at the top of the assembly.

6. Mark one carrier leg and bearing cap to correctlymatch the parts during carrier assembly. Mark theparts using a center punch and hammer. Figure 2.7.

NOTE: This capscrew had a “dry lock” patch onthreads during original assembly.

7. Remove the M8 capscrew that holds the opposite carrier bearing adjusting ring in position. Figure 2.8.

BEARINGCAP

CARRIERLEG

1002994a

MATCHMARKS

Figure 2.7

8. Remove the M20 capscrews and washers that holdthe two bearing caps on the carrier. Figure 2.10.

9. Remove the bearing caps and bearing adjustingrings from the carrier. Figure 2.11.

NOTE: On the HDL inlet side, the actuator sub-assembly, including the HDL piston, actuator, (2) D-rings, thrust bearing, (2) thrust washers, and thepiston housing will also be removed from inside thedifferential assembly when this adjusting ring isremoved. Figure 2.9.

Figure 2.8

Figure 2.6M8 SOCKET HEAD CAPSCREW

WASHER

HDL HYDRAULIC INLET PORT ASSEMBLY

CARRIER & CAP ASSEMBLY

BEARING ADJUSTING RING

PISTON HOUSING ASSEMBLY

PISTON ASSEMBLY

ACTUATOR

FRICTION DISC DRIVER

THRUST BEARING

TWO THRUST WASHERS

THRUST WASHER

FRICTION DISC

THRUST WASHER

DIAPHRAGM LEVER

PRESSURE PLATE

SHIMS

STATIONARY DISC

COVER HALF DIFF. CASE

FLANGE HALF DIFF. CASE


- 10 -

10. Remove HDL actuator sub-assembly from thecover case half. Figure 2.9.

WARNINGTake care when using lifting devices. When youuse a lifting strap, inspect the strap for damagebefore you use it. Do not use a lifting strap toshock load or drop load a component. Seriouspersonal injury and damage to components canresult. Place the ring gear and differential nestsafely on the work bench so personal injury willnot occur.

11. Safely lift the main differential and ring gearassembly from the carrier with bearing cups.Place the assembly on a work bench. Figure 2.12.

12. Remove the bearing cups.

HDL Differential Disassembly

WARNINGObserve all warnings and cautions provided bythe press manufacturer to avoid damage to components and serious personal injury.

NOTE: These M16 capscrews had a Loctite 242, orequivalent, applied at original assembly.

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BEARING

CAPBEARING

ADJUSTING

RING

1002997b

Figure 2.11

BEARING

CAP

1002996b

Figure 2.10

BEARING

CUP

BEARING

CUP

LEG

BORE

1002788d

Figure 2.12

Figure 2.9“D” RING

THRUSTWASHER PISTON

HOUSING

ADJUSTINGRING

HARDENED WASHER

PISTONTHRUSTBEARING

ACTUATOR

INLET PORTHEX SOCKETHEAD CAPSCREW

O-RING


- 11 -

1. The HDL components are in a separate cavity within the differential assembly. To remove the HDL components, loosen the (12) M16 sockethead capscrews that attach the ring gear to the differential case half.

2. If the match marks on the case halves of the differ-ential assembly are not visible, mark each casehalf with a center punch and hammer. Figure 2.13.

NOTE: These M12 capscrews had Loctite 680, orequivalent, applied at original assembly.

3. Remove the M12 capscrews and washers that holdthe case halves together.

4. Separate the case halves. If necessary, use abrass, plastic or leather mallet to loosen the parts.

5. Remove the (2) side gears and their washers, (4)planet pinions and their washers, differential spider.

6. Remove the HDL components: friction pack assembly, shims, pressure plate, thrust washer,diaphragm lever, thrust washer, and friction discdriver. Set all components aside for later inspectionand re-assembly.

7. If the ring gear requires replacement, use a pressto separate the case half and ring gear. Supportthe assembly under the ring gear with metal orwood blocks. Press the case half through the gear.Figure 2.14.

8. If the differential bearings need to be replaced, usea bearing puller or press to remove the bearingcones from the case halves. Figure 2.15.

HDL Carrier Input Pinion And Bearing Cage1. Fasten a yoke or flange bar to the input yoke or

flange. When the nut is removed, the bar will holdthe drive pinion in position. Yoke and flange bardetails are indicated in the tool section in this manual. Figure 2.16.

2. Remove the nut and washer from the drive pinion.

CAUTIONDo not use a hammer or mallet to loosen andremove the yoke or flange. A hammer or malletcan damage the parts and cause driveline runout,or driveline imbalance problems after carrier todriveline assembly.

NOTE: When removing the input yoke form the inputpinion shaft, the input yoke seal will be destroyed andreplacement seal will be required during later carrierreassembly.

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MATCH MARKS

MATCH MARKS

Figure 2.13

CASE HALF

PRESS

PLATE

1003002b

SUPPORTS

Figure 2.14

PULLER

PRESS

1002750b

Figure 2.15

Figure 2.16

FLANGEBAR


- 12 -

3. Remove the yoke or flange from the drive pinion.Do not use a hammer or mallet.

• If the yoke or flange is tight on the pinion: Use a Puller for removal. Figure 2.17.

NOTE: If the carrier being serviced has the trunnionfeature, then there are two seals in the bearing cageand the following extra step is recommended:

• After removing the outer seal, use a depthmicrometer to measure the dimension from thepinion cage surface to the inner pinion seal in atleast 3 positions and record this dimension forlater reference.

NOTE: These capscrews had Loctite 242 or similar,applied at original production assembly.

4. Remove the M12 capscrews and washers on thepinion bearing cage. Figure 2.18.

CAUTIONDo not use a pry bar to remove the bearing cagefrom the carrier. A pry bar can damage the bearing case, shims and carrier.

!

NOTE: The pinion bearing cage had Loctite 518, or similar, applied at both the carrier shell face bearing cage interface and to the top of the shimpack under the input bearing cage surface.

5. Remove the drive pinion, bearing cage and shimsfrom the carrier.

• If the bearing cage is tight in the carrier: Hit thebearing cage at several points around the flangearea with a leather, plastic or rubber mallet.Figure 2.19.

6. If the shims are in good condition, keep the shimstogether to use when the carrier is assembled.

7. If shims are to be discarded because of damage,first measure the total thickness of the pack. Makea note of the dimension. The dimension will beneeded to calculate the depth of the drive pinion in the carrier when gear set is installed.

Drive Pinion And Bearing Cage

WARNINGObserve all warnings and cautions provided bythe press manufacturer to avoid damage to components and serious personal injury.

CAUTIONDo not let the pinion assembly fall onto a hardsurface. A box containing soft packing materialcan be used to catch the pinion assembly.

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1003349a

DRIVE PINION AND BEARING CAGE

SHIMS

Figure 2.19

YOKE PULLER

FLANGE PULLER

1003348c

Figure 2.17

1003350a

BEARINGCAGE

CARRIER

Figure 2.18


- 13 -

1. Place the drive pinion and bearing cage in a press.The pinion shaft must be toward the top of theassembly. Figure 2.20.

2. Support the bearing cage under the flange areawith metal or wood blocks. Figure 2.21.

3. Press the drive pinion through the bearing cage.The inner bearing cone and bearing spacer willremain on the pinion shaft. Figure 2.20.

• If a press is not available: Use a leather, plasticor rubber mallet to drive the pinion through thebearing cage.

• Keep bearing spacer for later re-assembly.

CAUTIONBe careful when removing the seal. Do not damage the wall of bore. Damage to the bore wall can result in oil leaks.

!

BEARING

SPACER

SNAP

RING

INNER BEARING,

CUP AND CONE

SPIGOT

BEARING

DRIVE

PINION

OIL

SEAL

OUTER BEARING,

CUP AND CONE

1003008c

Figure 2.20

SUPPORT SPIGOT

BEARING

BEARING

CAGE

SUPPORT

PRESSDRIVE

PINION

OIL

SEAL

1003009c

Figure 2.21

4. Use a press and a sleeve to remove the unitized oil seal from the cage.

• If a press is not available: Place a tool with a flatblade under the flange to remove the oil sealfrom the cage. Figure 2.22.

5. If the pinion bearings need to be replaced, removethe inner and outer bearing cups from the inside ofcage. Use a press and sleeve, bearing puller or asmall drift hammer. The type of tool used dependson the design of the bearing cage. Figure 2.23.

When a press is used, support the bearing cageunder the flange area with metal or wood blocks.

BEARING

DRIVER

BEARING

PULLER

1003011f

Figure 2.23

1002437a

Figure 2.22


- 14 -

6. If the pinion bearings need to be replaced, removethe inner bearing cone from the drive pinion with apress or bearing puller. The puller MUST fit underthe inner race of the cone to remove the cone correctly without damage. Figure 2.24.

7. If the spigot bearing needs to be replaced, placethe drive pinion in a vise. Install a soft metal coverover each vise jaw to protect the drive pinion.

8. Remove the snap ring from the end of drive pinionwith snap ring pliers that expand. Figure 2.25.

9. Remove the spigot bearing from the drive pinionwith a bearing puller.

PRESS

SUPPORTS

DRIVE

PINION

INNER

BEARING

CONE BEARING

PULLER

1003012e

Figure 2.24

SPIGOT

BEARING

SNAP

RING

1003013c

Figure 2.25


- 15 -

WARNINGTo prevent serious eye injury, always wear safe eyeprotection when you perform vehicle maintenanceor service.

Solvent cleaners can be flammable, poisonousand cause burns. Examples of solvent cleanersare carbon tetrachloride, and emulsion-type andpetroleum-base cleaners. Read the manufacturer’sinstructions before using a solvent cleaner, thencarefully follow the instructions. Also follow theprocedures below.

• Wear safe eye protection.

• Wear clothing that protects your skin.

• Work in a well-ventilated area.

• Do not use gasoline, or solvents that containgasoline. Gasoline can explode.

• You must use hot solution tanks or alkalinesolutions correctly. Read the manufacturer’sinstructions before using hot solution tanks andalkaline solutions. Then carefully follow theinstructions.

• Remove gasket material from parts. Take carenot to damage ground surfaces.

• DO NOT clean ground or polished parts in a hotsolution tank, water, steam or alkaline solution.

Take care when you use Loctite® adhesive to avoidserious personal injury. Read the manufacturer’s instructions before using thisproduct. Follow the instructions carefully to prevent irritation to the eyes and skin.

Clean Rough Parts1. Clean rough parts with the same method as

cleaning ground and polished parts.

2. Rough parts can be cleaned in hot solution tankswith a weak or diluted alkaline solution.

3. Parts must remain in hot solution tanks until heated and completely cleaned.

4. Parts must be washed with water until all traces of the alkaline solution are removed.

Clean Ground And Polished Parts1. Use a cleaning solvent to clean ground or polished

parts or surfaces. Kerosene or diesel fuel oil canbe used for this purpose. Do not use gasoline.

2. Use a tool with a flat blade if required, to removesealant material from parts. Be careful not to damage the polished or smooth surfaces.

!

Figure 3.1

Yoke Seal Diameter3.000/3.005” (76.20/76.327mm)

Seal Journal Diameter

Unitized Pinion Seal (UPS)

CAUTIONDo not use hot solution tanks or water and alkaline solutions to clean ground or polishedparts. Damage to parts can result.

3. Do not clean ground or polished parts with water orsteam. Do not immerse ground or polished parts ina hot solution tank or use strong alkaline solutionsfor cleaning, or the smooth sealing surface may be damaged.

Clean And Inspect Yokes

CAUTIONDo not install a press on shaft excluder afterinstallation of a unitized pinion seal.

Do not use thin metal wear sleeves to refresh theyoke surface. Wear sleeves pressed onto the yokewill prevent correct seating of the pinion seal anddamage the pinion seal assembly. Wear sleeveusage will cause the seal to leak.

1. Clean the ground and polished surface of the yokejournal using a clean shop towel and a safe clean-ing solvent. Do not use gasoline, abrasive clean-ers, or scrubbers to clean yoke or flange surface.Do not attempt to polish the yoke.

NOTE: The unitized seal features a rubber innersleeve that is designed to seal and rotate with theyoke. This feature allows you to reuse a yoke withminor grooves.

2. Inspect the yoke seal surface for any grooves.

• If grooves are present, use calipers to measurethe groove diameters. If any of the yoke groovesmeasure less than the dimensions in Figure 3.1,replace the yoke.

!

!

Section 3Prepare Parts for Assembly

- 16 -

• The radius at the large-diameter end of the rollersis worn to a sharp edge. Figure 3.2.

• There is a visible roller groove in the cup or coneinner race surfaces. The groove can be seen atthe small- or large-diameter end of both parts.Figure 3.3.

• There are deep cracks or breaks in the cup, coneinner race or roller surfaces. Figure 3.3.

• There are bright wear marks on the outer surfaceof the roller cage. Figure 3.4.

Dry Parts After Cleaning1. Parts must be dried immediately after cleaning

and washing.

2. Dry the parts using soft, clean paper or cloth rags.

CAUTIONDamage to bearings can result when they arerotated and dried with compressed air.

3. Except for bearings, parts can be dried with compressed air.

Prevent Corrosion On CleanedParts1. Apply axle lubricant to cleaned and dried parts

that are not damaged and are to be assembled.Cover oiled parts to protect them from contami-nants in the air.

2. To store parts, apply a special material that prevents corrosion to all surfaces. Wrap cleanedparts in a special paper that will protect the partsfrom moisture and prevent corrosion.

Inspect Parts

Tapered BearingIt is very important to inspect all parts carefully andcompletely before the carrier assembly is assembled.Check all parts for wear and replace damaged parts.Replacement of damaged or worn parts will preventbreakdown of assembly later. Inspect the cup, cone,rollers and cage of all tapered roller bearings in theassembly. If any of the following conditions exist,replace the bearing.

• The large-diameter end of the rollers is worn levelwith or below the outer surface. Figure 3.2.

!

1003017aWORN SURFACE

WORN RADIUSFigure 3.2

1003018a

WEAR GROOVESCRACK

Figure 3.3

1003019a

WEAR MARKS

Figure 3.4


- 17 -

• There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. Figure 3.5.

• There is damage on the cup and cone inner racesurfaces that touch the rollers. Figure 3.6.

Pinion And Gear

CAUTIONA drive pinion and ring gear are machined as amatched set. Gears that are worn or damagedMUST be replaced as a matched set at the sametime. Do not mix old and new parts. Damage tocomponents can result.

1. Inspect the hypoid pinion and gear for wear anddamage. Replace worn or damaged gears as amatched set.

2. Verify the condition of the bearing cone seats and spline on the pinion shaft before installing newbearings, if necessary.

!

Main Differential Assembly

CAUTIONA thrust washer, differential side gear and piniongear are machined as a matched set. When youreplace any of these parts, you must install a newmatched set. Do not mix old and new parts.Damage to components can result.

Inspect the main differential assembly. Parts that aredamaged must be replaced. Inspect the followingparts for wear or stress. Figure 3.7.

• Inside surfaces of both case halves.

• Both surfaces of all thrust washers.

• Trunnion ends of the spider cross or differential pinion shaft.

• Teeth, splines and thrust surface of differential side gears.

• Teeth, bore and thrust surface of differential pinions.

Axle ShaftsInspect axle shafts for wear and cracks at the flange,shaft and splines. Replace the axle shafts, if required.

!

1003020a

ETCHING AND PITTING

Figure 3.5

1003021a

SPALLING AND FLAKING

Figure 3.6

1003022f

DIFFERENTIAL

CASE HALVES

DIFFERENTIAL

GEAR NEST

ASSEMBLY

Inspect

inside

surfaces.

PINION AND

THRUST

WASHER

Inspect.

SPIDER

(CROSS)Inspect.

Figure 3.7


- 18 -

Hydraulic Differential Components

CAUTIONInspect and replace all worn or damaged compo-nents. Splines and wear surfaces, including fric-tion surfaces are very critical. Use of worn com-ponents or components with cracks or other dam-age in combination with new components willresult in an early failure of the entire assembly.

• Inspect the stack of friction discs and stationarydiscs for wear scoring and spline damage. Worndiscs must be replaced as a complete stack. Do notmix new and worn disc in the same assembly.Figure 3.8.

• Inspect the friction disc driver for any wear or damage to either internal or external splines. Thiscomponent should be replaced if any splines aredamaged.

• Inspect all contact surfaces on both sides of thediaphragm lever wear. Inspect the diaphragm leverfor any cracks in each of the individual segments.Should any cracks be noted, this component shouldbe replaced.

• Inspect the thrust washers and pressure plate forwear on the mating surfaces. A light clean up isallowed with emery cloth or similar for moderatewear noted. Any significant wear, or deep grooves,will require this component to be replaced.

• Inspect the main case half assembly for wear andpossible other damage in the tang grooves for thefriction disc assembly tangs. Replacement is recommended if repair by emery cloth to removewear damage does not repair damage.

!

Hydraulic Actuation Components• Inspect Piston housing for wear and any scratch

damage at lead-in chamfers and on the bore surface that might cause the fluid to leak past the D-ring seals. If repair by light use of emery clothdoes not remove the damage, this componentshould be replaced. Figure 3.9.

• Inspect the piston for wear and any damage to anysurface that might cause the fluid to leak or to sealgrooves that might damage the D-rings. If lightrepair by emery cloth does not remove the damage,this component should be replaced.

• Inspect each of the D-rings for any damage of wear, signs of seal swell, or being torn. Replace the D-rings if any wear or damage is noted.

• Inspect the thrust bearing for signs of wear,brinelling, or damage. Replace component if anydamage is noted.

• Inspect the thrust washers for wear, or brinelling onthe mating surfaces. A light clean up is allowed withemery cloth or similar for moderate wear noted. Any significant wear, or deep grooves, will require thiscomponent be replaced.

• Inspect the hydraulic inlet port for any wear orcracks. Should wear be noted, or if any material isevident on O-ring groove surfaces, a light clean upis allowed with emery cloth or similar to remove anyscratches on the tube outer surface.

• Inspect the O-ring that is assembled on the outerdiameter of the inlet port shaft for any wear, swell, or tear damage. Replace the O-ring if any wear ordamage is noted.

Figure 3.8

FLANGE HALF DIFF CASEFRICTION DISCS ANDSTATIONARY DISCS

FRICTIONDISC DRIVER

THRUST WASHER

DIAPHRAGMLEVER

PRESSURE PLATE

SHIM

COVER HALF DIFF CASE

THRUST WASHER

Figure 3.9“D” RING

THRUSTWASHER PISTON

HOUSING

ADJUSTINGRING

HARDENED WASHER

PISTONTHRUSTBEARING

INLET PORTHEX SOCKETHEAD CAPSCREW

O-RING


- 19 -

Repair Or Replace PartsNOTE: Threads must be without damage and cleanso that accurate adjustments and correct torque values can be applied to fasteners and parts.

1. Replace any fastener if corners of the head are worn.

2. Replace washers if damaged.

3. Replace gaskets, oil seals or grease seals at thetime of carrier repair.

4. Clean parts and remove old silicone gasket material where required.

5. Remove nicks, mars and burrs from parts withmachined or ground surfaces. Use a fine file, Indiastone, emery cloth or crocus cloth.

6. Clean and repair threads of fasteners and holes.Use a die or tap of the correct size or a fine file.

FastenersRemoving Fasteners Secured WithAdhesiveIf it is difficult to remove fasteners secured with Dri-Lock®, AxleTech adhesive or Loctite 277®

adhesive, use the following procedure.

CAUTIONDo not exceed 177° C (350° F) maximum. Heatingmust be done slowly to prevent thermal stressesin the other components.1. Heat the fastener for three to five seconds. Try to

loosen the fastener with a wrench. Do not use animpact wrench or hit the fastener with a hammer.

2. Repeat Step 1 until you can remove the fastener.

New Fasteners With Pre-Applied AdhesiveNOTE: No drying time is required of fasteners withpre-applied adhesive.

1. Use a wire brush to clean the oil and dirt fromthreaded holes.

2. Install new fasteners with pre-applied adhesive toassemble parts. Do not apply adhesives orsealants to fasteners with pre-applied adhesive, or to fastener holes.

3. Tighten the fasteners to the required torque valuefor that size fastener. Refer to “Torque Table” inSection 6, when tightening all fasteners.

!

Original or Used FastenersUse a wire brush to clean the oil, dirt and old adhesive from all threads and threaded holes.

Welding RepairThe carrier shell assembly housing material is Notsuitable for welding repair. Do not attempt to repairweld this carrier shell assembly.

Silicone Gasket Material

WARNINGRead the manufacturer’s instructions before usinga silicone gasket material, then carefully followthe instructions. If a silicone gasket material getsinto your eyes, follow the manufacturer’s emer-gency procedures. Have your eyes checked by aphysician as soon as possible.

1. Use a tool with a flat blade, if required, to removeall old gasket material from surfaces. Figure 3.10.

2. Use a non-residual cleaning solvent to clean thesurfaces where you will apply silicone gasket mate-rial. Do not use petroleum cleaners such as miner-al spirits and lacquer thinner as they leave aresidue that prevents adhesion. Remove all oil,grease, dirt and moisture without damaging themating surfaces. Figure 3.10.

3. Dry surfaces.

!

1003027c

Remove old

sealant material.

Figure 3.10


- 20 -

Gear SetsRefer to the following examples for information onidentifying gear sets with matched parts. Alwayscheck match numbers to verify that the gear set youwill install has matched parts. Figure 3.11.

ExamplesGear Set Tooth Combination Number

Gear Set Match NumberNOTE: AxleTech’s drive pinions and ring gears areonly available as matched sets. Each gear in a sethas an alpha-numeric match number.

Pinion Cone Variation NumberNOTE: Don’t use the pinion cone variation numberwhen you check for a matched gear set. Use thisnumber when you adjust the pinion depth in the carrier. Refer to Section 4.

Carrier AssemblyGeneral comments to be applied to the CarrierAssembly Procedures and Recommendations:1. Clean and dry all surfaces to which sealant or

adhesive will be applied.2. Clean and dry all threads of capscrews or holes

to which thread locker will be applied.3. Apply thread locker to capscrew threads in a

through holes,and into tapped holes when blindholes are required.

4. All fastener torques and recommended thread locker types are located in a table listed in the“Fastener Torque” section in this manual by threadsize and location.

5. Torquing of all capscrews is to be done in a crossing pattern for even clamping.

6. Taper bearing cones and cups must be from thesame bearing vendor. Do Not mix cups and conesin mating assemblies or same axle wheel end.

7. After pressing a bearing cone/cup into an assem-bly, use a 0.025mm (0.001”) feeler gauge to verifyassembly is properly installed against bearing cupshoulder.

8. Mating surfaces between 2 components must be free of “positive” indentations (with materialabove surface). Minor “negative” indentations are permitted.

9. Functional critical surfaces must be free fromdefects. Friction faces on the wet brake /Hydraulicdifferential lock stationary discs and reactionplates. Piston bores of the wet brake and Hydraulic differential lock components. Seal races or seat, O-Ring sealing surfaces.

10. Use of the correct assembly tools are recom-mended to assure a quality rework on these axlecomponents. A listing of the recommendedassembly tools is indicated in the “Special Tools”section and are available upon request. Use ofincorrect assembly tools may cause damage tocomponent being installed and other componentsassociated with component being assembled.

4

5

1

2 3

1003031a

Figure 3.11

ALTERNATE LOCATIONS:

1 PART NUMBER, TOOTH COMBINATIONNUMBER, GEAR SET MATCH NUMBER, PINIONCONE VARIATION NUMBER

2 PART NUMBER, TOOTH COMBINATIONNUMBER

3 GEAR SET MATCH NUMBER, PINION CONEVARIATION NUMBER

4 PART NUMBER, TOOTH COMBINATIONNUMBER, GEAR SET MATCH NUMBER

5 PART NUMBER, TOOTH COMBINATIONNUMBER GEAR SET MATCH NUMBER

Drive Pinion Ring GearGear Set Teeth Location Location8-41 = gear set has a At the end at threads On the front faceeight-tooth drive or outer diameterpinion and a 41-toothring gear

Drive Pinion Ring GearMatch Number Location LocationM29 At the end of the gear On the front face

head or outer diameter

Pinion Cone (PC)Variation Drive Pinion Ring GearNumber Location LocationPC+3 At the end of the On the outer+2 pinon gear head diameter+0.01 mmPC-5–1–0.02 mm


- 21 -

11. All friction discs must be pre-soaked for at least12 hours in axle oil prior to installation. Frictiondiscs should then be hung to drain excess lubri-cant for 15-30 minutes prior actual assembly intothe carrier or axle assembly.

12. Following the final axle assembly, there are 4 axletests that should be performed to help assure aquality re-assembly.(Information on each of thesetests are located in the assembly section as theaxle group is assembled or in the carrier manual5.4 for the carrier test if done separately prior axlere-installation).a. Carrier Hydraulic Differential Functional and

Leak Test.b. Wet Disc Brake Functional and Leak test.(if

equipped).c. Axle Air Leak Test.d. Axle Spin Test.

A.O. SPEC DESCRIPTION APPROVED COMPOUND WHERE USED

Diff. case bearing cupSTF 02-452 Retaining compound, anaerobic Loctite® 680TM

STF 02-435 Sealant, anaerobic flexible Loctite 518 Pinion cage shim pack

Diff. case bearing cupSTF 02-458 Retaining compound, anaerobic Loctite® 635TM

Loctite® 5699TM Input yoke splinePermatex® 82194 HDL inlet port

STF 02-437 Sealant, RTV non-corrosive Three Bond 1216 Ring gear thrust screwThree Bond 1216E Housing, carrier face

Thread Locker’s, Adhesives, SealantsAxleTech “STC” specs for organic materials is called out across the text. Use table below to identify approved compounds.

BASIC/TOTAL 0.1 0.3 0.8

0.0

0.1 1

0.2 2

0.3 1

0.4 1 1

0.5 2 1

0.6 2

0.7 1 2

0.8 1

0.9 1 1

1.0 2 1

1.1 1 1

1.2 1 1 1

1.3 2 1 1

1.4 2 1

1.5 1 2 1

1.6 2

Shim table - preload of HDL disc packDisc pack should be correctly preloaded for proper function of HDL. Use table below to compound w/minimum number of basic shims.


- 22 -

WARNINGTo prevent serious eye injury, always wear safeeye protection when you perform vehicle maintenance or service.

Use a brass or leather mallet for assembly anddisassembly procedures. Do not hit steel partswith a steel hammer. Pieces of a part can breakoff and cause serious personal injury.

Observe all warnings and cautions provided bythe pressmanufacturer to avoid damage to components and serious personal injury.

WARNINGTake care when you use Loctite® adhesive to avoidserious personal injury. Read the manufacturer’s instructions before using thisproduct. Follow the instructions carefully to prevent irritation to the eyes and skin.

AssemblyDrive Pinion, Bearings And Bearing Cage1. Place the bearing cage in a press. Figure 4.1.

2. Support the bearing cage with metal or woodblocks.

NOTE: Use the same procedure for both bearingcups.

3. Press both bearing cups into the bore of bearingcage until cup is flat against bottom of bore. Use asleeve of the correct size to install bearing cup.Figure 4.1.

!

!4. Place the drive pinion in a press with the gear head

or teeth facing down. Figure 4.2.

5. Press the inner bearing cone on the shaft of thedrive pinion until the cone is flat against the gearhead. Use a sleeve of the correct size against thebearing inner race.

InstallationOne-Piece Spigot Bearing On The DrivePinion With Snap-Ring1. Place the drive pinion in a press with the gear head

or the teeth facing up. Figure 4.3.

2. Press the spigot bearing on the end of drive pinion.The bearing must be flat against the gear head.Use a sleeve of the correct size against the bearing inner race. Figure 4.3.

CAGE

SUPPORTS

PRESSSLEEVE

BEARING

CUP

1003033b

Figure 4.1

SLEEVE

INNER BEARING CONE

1003120b

Figure 4.2

PRESS

SLEEVE

SPIGOT

BEARING

1003034b

Figure 4.3

Section 4Assembly

- 23 -

3. Use snap ring pliers to install the snap ring into thegroove in the end of the drive pinion. A check isrecommended to assure the snap ring is properlyseated by rotating the snap ring freely in the snapring groove. Figure 4.4.

Drive Pinion Assembly1. Apply axle lubricant to the bearing cups and to

the bearing cones in the cage.

2. Install the drive pinion into the bearing cage.

3. Install the bearing spacer or spacers onto the pinion shaft against the inner bearing cone. Figure 4.5.

The spacer or spacers control the preload adjustmentof the drive pinion bearings.

4. Press the outer bearing cone onto the pinion shaftagainst the spacer. Do not install the pinion seal inthe bearing cage. Figure 4.5.

AdjustmentPinion Bearing PreloadPress Method

NOTE: Do not read starting torque. Read only thetorque value after the cage starts to rotate. Startingtorque will give an incorrect reading.

1. Place the drive pinion and cage assembly in apress, gear head or teeth toward the bottom.

2. Install a sleeve of the correct size against the innerrace of the outer bearing. Figure 4.6.

3. Apply 54,000 lbs. (240 kN) load to outer bearingcone through a sleeve. As pressure is applied,rotate the bearing cage several times, by hand with load applied in order to seat bearings.

4. While pressure is held against the assembly, winda cord around the bearing cage several times.

5. Attach a spring scale to the end of the cord.

6. Pull the cord on a horizontal line. As the bearingcage rotates, read the value indicated on the scale.Record the reading. Figure 4.6.

SNAP

RING

SPIGOT

BEARING

1003035b

Figure 4.4

INNER

BEARING

CONE

DRIVE

PINION

OUTER

BEARING

CONE

BEARING

SPACER

BEARING

CAGE

1003043a

Figure 4.5

PRESS

1003044b

SLEEVE

Figure 4.6

Section 4Assembly

- 24 -

7. Measure the diameter of the bearing cage wherethe cord was wound. Measure in inches or centimeters. Figure 4.7.

8. Divide the dimension in half to get the radius.Record the radius dimension.

9. Use the following procedure to calculate the bearing preload or torque.

• Pounds Pulled x Radius (inches) = lbf-in Preload-Preload x 0.113 = N•m Preload• Kilograms Pulled x Radius (cm) = kgf-cmPreload-Preload x 0.098 = N•m Preload

or

Examples• Reading from spring scale = 7.5 pounds (3.4 kg)

• Diameter of bearing cage = 6.62-inches (16.8 cm)

• Radius of bearing cage = 3.31-inches (8.4 cm)7.5 lb x 3.31 in = 24.8 in-lb PreloadPreload x 0.113 = 2.8 N•m Preload

or3.4 kg x 8.4 cm = 28.6 kg-cm PreloadPreload x 0.098 = 2.8 N•m Preload

10. If the preload or torque of pinion bearings is notwithin 5-45 lb-in (0.56-5.08 N•m) for new pinionbearings or 10-30 lb-in (1.13-3.39 N•m) for usedpinion bearings in good condition, adjust thespacer and repeat Steps 1 through 9.

• To increase preload: Install a thinner bearing spacer.

• To decrease preload: Install a thicker bearing spacer.

Seal InstallationAfter the pinion bearing preload is correct, then thepinion seal(s) can be installed.

Input Bearing Cage Less-Trunnion Option1. Remove the replacement unitized seal,

A-1205-N-2588, from the package. Figure 4.8.

2. Select the R4422401 seal driver. Each seal driveris designed to correctly install a specific diameterseal. To determine the yoke seal diameter, measure the yoke journal. To obtain seal driver KIT 4454, call 1-877-547-3907.

3. Position the seal on the driver.

CAUTIONUse a rubber mallet and driver to install the seal.Do not use a steel, brass or plastic hammer.Damage to the seal and driver tool can result.

4. Use a rubber mallet and driver to drive the seal intoor against the bearing cage. The seal must fullyseat into or against the bearing cage.

5. Use a 0.010-inch (0.25 mm) feeler gauge to checkfor clearance between the entire seal flange circumference and the bearing cage.

!

Measure diameter of cage. 1003045b

Figure 4.7

Figure 4.8

UNITIZED SEAL

Section 4Assembly

- 25 -

If the 0.010-inch (0.25 mm) Max. feeler gaugeslides between the seal flange and bearing cage:Correctly position the seal driver and drive the sealinto the bore until the 0.010-inch (0.25 mm) shim cannot slide between the seal flange and bearingcage at any point around the seal flange. Figure 4.9.

NOTE: Does not apply to trunnion version.

Input Bearing Cage - With TrunnionNOTE: The trunnion configuration can not bechecked in this same review method. For the trunnion design, the following procedure is recommended to check the input seal installation.

A. Prior to the seal installation, using the depthmicrometer measure the distance in at least threepositions from the top of the input bearing cage to the machined seal surface in the bearing cage. Figure 4.10.

B. Measure the seal flange thickness and add 0.010”(0.254mm).

C. Subtract B from A to obtain an approximate maximum measurement value, when the seal isinstalled square in the input bearing cage. Theseal depth in the input cage must vary less than0.010 inch (0.25mm).

Yoke

CAUTIONDo not use thin metal wear sleeves to refresh theyoke surface. Wear sleeves pressed onto the yokecan prevent correct seating of the pinion seal,damage the pinion seal assembly and can causethe seal to leak. Damage to components canresult.

NOTE: Once the yoke is partially or fully installed andthen removed for any reason, the unitized pinion sealwill be damaged and unusable. If the yoke and unit-ized pinion seal are removed after partial or full instal-lation, remove and discard the original unitized pinionseal and replace it with another new unitized pinionseal. Refer to the Seal Installation procedure in thissection.

1. Before you install the yoke, apply a 3.0mm bead ofsealant STF 02-437 to the bearing end of yokespline. Apply oil on seal I.D. and yoke seat including lead chamber.

2. Align the yoke splines with the shaft splines. Slidethe yoke over the shaft spline.

CAUTIONDo not use a hammer or mallet to install the yoketo the input pinion shaft. Using a hammer or mallet can damage the yoke or flange.

3. Press the input yoke flange onto the drive pinionshaft. The yoke or flange must be fully seatedagainst the outer differential bearing before the nutis torqued to specifications.

Shim Pack Thickness For A NewDrive Pinion

WARNINGTake care when you use Loctite® adhesive to avoidserious personal injury. Read the manufacturer’s instructions before using thisproduct. Follow the instructions carefully to prevent irritation to the eyes and skin.

!

!

!0.010" (0.254 mm) Max

Figure 4.9

Figure 4.10

MEASUREBEFORE

0.010 INCH(0.25MM)MAXIMUMINSTALLEDVARIATION

Section 4Assembly

- 26 -

NOTE: Use this procedure if you’ll install a new drivepinion and ring gear set, or if you have to adjust thedepth of the drive pinion. Figure 4.11.

1. Use a micrometer to measure the thickness of theshim pack that was removed from under the pin-ion cage. Record the measurement. Figure 4.12.

2. Find the pinion cone (PC) variation number on thedrive pinion you’ll replace. Figure 4.13.(1003056b) Record the number. The pinion conenumber can be one of the following values.

PC +3, PC -3, +3 or -3 = 0.003-inch

PC +.03, PC 0.03 mm, +0.03 mm or-0.03 = 0.03 mm

3. If you can’t find the PC number or it’s unreadable,install a new shim pack of the same thickness thatyou measured in Step 1.

4. If the old pinion cone number is a plus (+) number,subtract the number from the old shim pack thickness that was measured in Step 2.

5. If the old pinion cone number is a minus (-) number, add the number to the old shim packthickness that was measured in Step 2.

6. Find the pinion cone (PC) variation number on thenew drive pinion that will be installed. Record thenumber.

1003055a

Figure 4.12

PINION CONE VARIATION NUMBER

1003056b

Figure 4.13

CARRIER

BEARING CAGE

SHIM PACK CONTROLS DEPTH

OF PINION

1003054b

Figure 4.11

INPUT PINION BEARING CAGEWITH TRUNNION OPTION

Section 4Assembly

- 27 -

7. If the new pinion cone number is a plus (+) number, add the number to the standard shimpack thickness that was calculated in Step 4 orStep 5. Use new shims to make a shim pack tothe correct thickness. Refer to Table B.

8. If the new pinion cone number is a minus (-) number, subtract the number from the standardshim pack thickness that was calculated in Step 4or Step 5. Use new shims to make a shim pack tothe correct thickness. Refer to Table B.

Table B

InstallationDrive Pinion, Bearing Cage And ShimPack Into The CarrierNOTE: If a new drive pinion and ring gear set isinstalled, or if the depth of the drive pinion has to beadjusted, calculate the thickness of the shim pack.Refer to the procedure Shim Pack Thickness for aNew Drive Pinion.

NOTE: Shim Pack controls the axial position of thedrive pinion in relation to the ring gear.

1. Select the correct shim pack and install it betweenthe bearing cage and carrier. Figure 4.14.

2. Apply 1.5mm bead of Loctite 518 to carrier face.

3. Align the oil slots in the shims with oil slots in thebearing cage and carrier. Use guide studs to helpalign the shims. Figure 4.15.

4. Apply 1.5mm bead of sealant STF 02-435 to bothsides of the shim pack.

5. Install the drive pinion and bearing cage into thecarrier. If necessary, use a rubber, plastic orleather mallet to hit the assembly into position. Figure 4.15.

6. Remove guide studs from assembly.

Examples Inches mm

1. Old Shim Pack Thickness. 0.030 - 0.002 0.760 - 0.050Old PC Number, PC = 0.028 + 0.005 = 0.710 + 0.130+2 inches (+0.05 mm) = 0.033 = 0.840Standard Shim PackThickness. New PCNumber, PC +5 inches(+0.13 mm)New Shim Pack Thickness

2. Old Shim Pack Thickness 0.030 + 0.002 0.760 + 0.050Old PC Number, PC = 0.032 + 0.005 = 0.810 + 0.130-2 inches (-0.05 mm) = 0.037 = 0.940Standard Shim PackThickness. New PCNumber, PC +5 inches(+0.13 mm)New Shim Pack Thickness

3. Old Shim Pack Thickness 0.030 - 0.002 0.760 - 0.050Old PC Number, PC = 0.028 - 0.005 = 0.710 - 0.130+2 inches (+0.05 mm) = 0.023 = 0.580Standard Shim PackThickness. New PCNumber, PC -5 inches(-0.13 mm)New Shim Pack Thickness

4. Old Shim Pack Thickness 0.030 + 0.002 0.760 + 0.050Old PC Number, PC = 0.032- 0.005 = 0.810 - 0.130-2 inches (-0.05 mm) = 0.027 = 0.680Standard Shim PackThickness. New PCNumber, PC -5 inches(-0.13 mm)New Shim Pack Thickness

CARRIER

GUIDE STUDS

1003354b

Figure 4.14

SHIMS

DRIVE PINIONAND BEARING CAGE

CARRIER

1003355c

Figure 4.15

Section 4Assembly

- 28 -

7. Install the bearing cage-to-carrier (M12) cap-screws and washers. Tighten the capscrews tothe correct torque value. Figure 4.16. Refer to“Torque Table” in Section 6.

8. Install the drive pinion nut (M39) and washer onthe input pinion shaft and against the yoke collar.Tighten the nut against yoke collar to torque specifi-cations. Refer to “Torque Table” in Section 6.

AssemblyMain Differential And Ring GearAssembly Of HDL DifferentialCAUTION

Heat the ring gear before seating it onto the differential case. Do not press a cold ring gearon the flange case half. A cold ring gear willdamage the case half because of the tight fit.

1. Heat the ring gear in a tank of water to a tempera-ture of 194°F-212°F (90°C-100°C) for 10 to 15 minutes. Alternative heating methods may beused. Temperatures not to exceed: 170°C (340°F)at web and 120°C (250°F) at the teeth.

WARNINGWear safe clothing and gloves when workingwith the hot ring gear to prevent serious personal injury.

2. Use a lifting tool to safely lift the ring gear fromthe tank of water.

3. Install the ring gear on the flange case half immediately after the gear is heated. If the ringgear does not fit easily on the case half: Heat the gear again.

!

4. Align the ring gear and the flange case half fas-tener holes. Rotate the ring gear as necessary.Figure 4.17.

5. Use a press and the correct size sleeve to installthe bearing cones on the cover case half and theplain case half. Figure 4.18.

6. Apply axle lubricant on the inside surfaces of bothcase halves, spider or cross, thrust washers, sidegears and differential pinions.

7. Place the flange case half on a bench with thering gear teeth toward the top.

NOTE: There is no thrust washer behind this sidegear of an HDL differential.

8. Install side gear into flange half.

Figure 4.17

CASE HALF

SUPPORTSUPPORT

PRESS

SLEEVE

BEARING CONE

1003065a

Figure 4.18

1001059a

Figure 4.16

Section 4Assembly

- 29 -

FLANGECASEHALF

RINGGEAR

10. Install the spider or cross, differential pinions and thrust washers into the flange case half.Figure 4.19.

11. Install the second side gear and thrust washerover the spider and meshing with differential pinions. Figure 4.20.

NOTE: Tangs in side gear thrust washers should fitinto slots on plain case half. Lubrication groovesshould face toward gear.

12. Place the plain half of the differential case overthe flange half and gears. Rotate the plain half toalign the match marks. Figures 4.20 and 4.21.

NOTE: Add drops of STF 02-452 thread locker to the fastener holes prior to inserting capscrews and washers per Torque Table in section 6.

13. Install the (16) M12 fasteners and washers intothe case halves. Refer to Section 3.

A. Install four capscrews and washers into thecase halves. The distance between the fas-teners must be equal. Tighten the fasteners tothe correct torque value in a progressivecriss-cross pattern opposite each other. Referto “Torque Table” in Section 6. Figure 4.22.

B. Install the other fasteners into the case halves.Tighten the fasteners to the correct torquevalue. Refer to “Torque Table” in Section 6.

2

12

7

395

111

8

410 6

13

14

15

161003070a

Figure 4.22

THRUSTWASHER

SIDEGEARPLAIN

CASEHALF

1003068b

Figure 4.20

1003069f

PLAIN CASEHALF

MATCHMARKS

Figure 4.21

SPIDER, PINION

AND THRUST

WASHERS

1003067a

Figure 4.19

Section 4Assembly

- 30 -

HDL Discs, Diaphragm Lever,Diff Case1. Pre-soak HDL discs in oil for at least 12 hours

prior to installation.

2. Place main case assembly — completed in previous steps — on a bench w/ ring gear facingdown. Figure 4.23.

3. Place disc driver over side gear hub.

4. Install stationary disc into flange case half, aligning tangs in discs w/ slots in case.

5. Install friction disc onto disc driver, aligningsplines. Align lubrication slots among frictiondiscs.

6. Repeat steps 4-5, until disc pack is complete. End w/ a stationary disc.

7. Place a 0.8-thick shim over last stationary disc.

NOTE: Initial shim pack thickness for measurementpurpose only.

8. Place pressure plate over shim pack. Figure 4.24.

9. Place cover case half on a bench w/ bearing conefacing down.

10. Apply grease to one side of large thrust washerand install large thrust washer with grease sidedown into cover case half. Figure 4.24.

11. Apply oil to both sides of diaphragm lever.

12 Place diaphragm lever with smaller side of centerfingers facing down toward cover case half, small diameter of diaphragm lever is down.

13. Apply grease to surfaces on cover case half thatwill contact side gear washer.

14. Install side gear thrust washer with grooves facing upward (away from cover case half) intocover case half.

HDL Discs - Initial Selection OfShim Pack For Preload1. Lift cover case half assembly from bench.

2. Stick a finger through case bore from bearing sideto hold diaphragm lever in place.

3. Flip cover case half assembly and place it overmain diff case subassembly. Figure 4.25.

4. Place a 30-35 kg (66-77 lb) weight over covercase half, keeping it balanced.

Figure 4.23

Figure 4.24

PRESSUREPLATE

SHIMS

FRICTION DISC

STATIONARYDISC

DISC DRIVER

MAIN CASEASSEMBLY WITHRING GEAR

SIDE GEAR THRUSTWASHER

DIAPHRAGMLEVER

THRUSTWASHER

COVER CASEHALF WITHBEARING

Figure 4.25COVER CASEHALF ASSEMBLY

MAIN DIFF CASESUBASSEMBLY

Section 4Assembly

- 31 -

5. Measure gap between cover case half and flangecase half in 3 places equally spaced. If gap iszero in any of the 3 places, replace shim (initial was 0.8 mm) with a thicker shim and repeatthe measurement again. Figure 4.26. Adjust shimpack. See step 7.

6. Calculate: <shim pack thickness> = <initial shimpack> - <average gap> + 0.5

Example:Measured gaps: 0.68, 1.01, 0.96

Shim pack = 0.8 - (0.68+1.01+0.96)/3 + 0.5 = 0.417==> 0.4

7. Combine basic shims — 0.1, 0.3 and 0.8 mm —to get the required thickness w/ minimum number of shims.

Example:0.4 = 0.1x1 + 0.3x1

HDL Discs - Final Assembly1. Remove cover case half assembly —

w/ diaphragm lever and washers.

2. Remove pressure plate.

3. Replace initial 0.8-thick shim w/ shim pack calcu-lated in previous steps (0.4-thick in example).

4. Place pressure plate over shim pack.

5. Place cover case half assembly — w/ diaphragmlever and thrust washers — over main diff caseassembly.

6. Slide actuator through bore in cover case half.Engage its slots w/ slots in diaphragm lever.Rotate actuator by hand to check if engaged. Itshould oscillate less than 1 degree.

7. Slide an axle shaft through driver and side gearsplines.

NOTE: A special tool can be made for this purposeFigure 4.27.

8. Install 2 ring gear-to-case capscrews (spaced180°) and lightly tighten w/ an impact wrench.Make sure there’s no gap between cover case halfand flange case half.

9. Measure torque required to turn axle shaft (a.k.a. “diff gears rotating resistance”).Figure 4.28.

Spec: 100-220 N•m (74-162 lbf.ft)

NOTE: A torque multiplier may be required.

10. If necessary, remove gear-to-case capscrewsand repeat steps 1-9 adjusting shim pack. Addshims to increase preload; remove shims todecrease preload. Preload varies approximately110 N•m (80 lbf.ft) for every 0.1 mm of shim.

11. Remove HDL actuator and axle shaft.

12. Install all ring gear-to-case capscrews (M16).Refer to “Torque Table” in Section 6.

Figure 4.28

Figure 4.26 COVER CASEHALF ASSEMBLY

MEASURE GAP 3PLACES EQUALLYSPACES

MAIN DIFF CASESUBASSEMBLY

1003071a

APPROXIMATELY 304.8 MM (12-INCHES)

SIDE VIEWWELD NUT

TO END OF SHAFT

END VIEW

Figure 4.27

Section 4Assembly

- 32 -

13. Use a 0.003-inch (0.08 mm) feeler gauge tocheck for gaps between the back surface of thering gear and the case flange. Check for gaps atfour points around the assembly. If the gapsexceed specifications: check the flange case halfand ring gear for the problem that causes thegap. Repair or replace parts. Assemble the ringgear on the flange case half.

Spec: Not to exceed 0.075mm (0.003”).

HDL Piston1. Install D-seals into piston grooves. Figure 4.29.

2. Apply oil to piston bores in piston housing, including lead chamfer area.

3. Place piston housing in a press, with piston boresfacing up.

4. Place piston assembly on piston housing.

5. Check that the piston assembly rotates 15-20degrees easily by hand, indicating the pistonassembly is well centered and seated against thelead chamfer.

6. Press piston assembly into piston housing, keep-ing it parallel.

CAUTIONCocking of the piston assembly will cause it tobind in the bores, which may scratch critical seal surfaces.

InstallationDifferential And Ring Gear AssemblyInto Carrier1. Apply 1.5mm x 360 degree bead of adhesive

STF 02-452 or STF 02-458 to bearing bores in carrier and bearing caps. Apply adhesive aroundthe circumference of the smooth, ground surfacesonly. Do not place adhesive on threaded areas.Figure 4.30. Do not get oil on the outer diameterof the bearing cup and do not permit oil to driponto the bearing bores.

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NOTE: After complete application, liquid anaerobiccompounds can be left in place for a short time.However, they will generate a skin where they are incontact with metal surfaces as metal contact alsoactivates the polymerization process. A thick skin willprevent the material from flowing uniformly into theassembled joint. You must complete the procedurewithin two hours from the time you apply the adhe-sive. If two hours have passed since application,clean the adhesive from the parts and apply newadhesive.

2. Install the bearing cups over the bearing conesthat are assembled on the case halves. Figure 4.31.

3. Safely lift the differential and ring gear assemblyand install it into the carrier. The bearing cupsmust be flat against the bores between the carrierlegs. Figure 4.31.

BEARING

CUP

BEARING

CUP

LEG

BORE

1002788d

Figure 4.31

ADHESIVE BEARING CAP

CARRIER LEG

1003026d

Figure 4.30

Figure 4.29

Section 4Assembly

- 33 -

PISTON ASSEMBLY

PISTON HOUSING

4. Install the thrust washer, thrust bearing and thrustwasher on the HDL actuator pilot. Figure 4.32.

5. Slide the actuator through the bore in the covercase half. Engage the actuator slots with slots inthe diaphragm lever.

NOTE: The actuator should rotate less than 1degree, indicating it’s engaged with the diaphragmlever.

NOTE: Actuator flange should have approximately11 mm (0.43”) gap relative to the differential case.

6. Install the HDL piston housing into the HDL sideadjusting ring.

7. Install both of the bearing adjusting rings into position between the carrier legs. Turn eachadjusting ring hand-tight against the bearing cup.Figure 4.32.

8. Install the bearing caps over the bearings andadjusting rings. Align the match marks you madewhen you removed the caps. Figure 4.33.

CAUTIONIf bearing caps are not installed in correct locations, the bores and threads in caps will notmatch the carrier. You will have problems assem-bling the caps on the carrier and damage toparts can occur. Do not force the bearing capsinto position.

9. Seat each bearing cap with a light leather, plasticor rubber mallet. The caps must fit easily againstthe bearings, adjusting rings and carrier. Do notforce the bearing caps into position.

• If bearing caps do not correctly fit into position:Check the alignment of match marks betweencaps and carrier. Remove the caps and repeatSteps 6-8.

10. Install the (M20) capscrews and washers thathold bearing caps to the carrier. Refer to the“Torque Table” in section 6.

11. Adjust differential bearing preload and hypoidgear backlash. Check the tooth contact patterns.

Adjust Differential Bearing Preload1. Hand-tighten both adjusting rings against the

differential bearings.

2. Use a micrometer to measure distances X and Ybetween the opposite surfaces of the bearingcaps. Figures 4.34 and 4.35. Record the measurements.

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1003082d

Figure 4.34

MATCH

MARKS

BEARING

CAP

1002790c

Figure 4.33

Figure 4.32

PISTON HOUSING (PISTON AND D-RINGSINSTALLED)

ADJUSTING RING

THRUSTWASHERSAND BEARING

ACTUATOR

Section 4Assembly

- 34 -

3. Tighten each bearing adjusting ring one notch.

4. Measure distance X and Y again. Compare themeasurements with the ones you obtained in Step2. The difference between these dimensions is theamount the bearing caps have expanded.

Example• Measurements of RS-145 carrier

• Distance X or Y

- before tightening adjusting rings =

13.927-inch (353.74 mm).

• Distance X or Y

- after tightening adjusting rings =

13.936-inch (353.97 mm)

• 13.936-inch - 13.927-inch = 0.009-inch

(0.23 mm) difference/expansion.

• If the expansion is within specifications: Continueby checking ring gear runout. Specification: 0.05-0.22mm (0.002-0.009”).

• If the dimension is less than specifications: RepeatSteps 3 and 4 as needed.

Check Ring Gear Runout1. Attach a dial indicator onto the carrier mounting

flange. Figure 4.36.

2. Adjust the dial indicator so that the plunger orpointer is against the back surface of the ringgear. Set the dial indicator to ZERO.

3. Rotate the differential and ring gear. Read the dialindicator. Runout must not exceed 0.008-inch(0.20 mm). Figure 4.36.

• If runout exceeds specifications: Remove the differential and ring gear assembly from the carrier.Refer to HDL Differential Disassembly in Section 2and Steps 4 below.

• If runout is within specifications: Proceed to Ring Gear Backlash Adjustment.

4. Install the differential and ring gear into the carrier.Refer to Main Differential and Ring GearAssembly of HDL Differential in this section.Repeat preload adjustment of differential bearings.

Ring Gear Backlash Adjustment

MICROMETER

1003083d

Figure 4.35

Rotate ring gear.

DIAL INDICATOR

1003084c

Figure 4.36

Ring Gear Range of Backlash Backlash SettingPitch Diameter Setting for New Gear Sets

Less than 0.008-0.018-inch 0.012-inch17-inches (0.20-0.46 mm) (0.30 mm)(431.8 mm)

Greater than 0.010-0.020-inch 0.015-inch17-inches (0.25-0.51 mm) (0.38 mm)(431.8 mm)

Section 4Assembly

- 35 -

Measure the outer diameter of ring gear for approximate pitch diameter. Figure 4.37.

• If the old gear set is installed: Adjust the back-lash to the setting that was measured before thecarrier was disassembled.

• If a new gear set is installed: Adjust the backlashto the correct specification for new gear sets.

After checking the tooth contact patterns, the backlash can be adjusted within specification limits,if needed. To change the location of the pattern usethe following procedures.

1. Attach a dial indicator onto the mounting flange ofthe carrier. Figure 4.38.

2. Adjust the dial indicator so that the plunger orpointer is against the tooth surface. Figure 4.38.

3. Adjust the indicator dial to ZERO. Hold the drivepinion in position.

4. After reading the dial indicator, rotate the differential and ring gear a small amount in bothdirections against the drive pinion teeth.

• If the backlash reading is within specifica-tions: Check the tooth contact patterns.

• If the backlash reading is not within specifications: Adjust backlash as needed.

5. Loosen one bearing adjusting ring one notch thentighten the opposite ring the same amount.

• To increase backlash: Move the ring gear awayfrom the drive pinion. Figure 4.39.

• To decrease backlash: Move the ring geartoward the drive pinion. Figure 4.40.

NOTE: When you adjust backlash, move the ringgear only. Do not move the drive pinion.

6. Repeat Steps 2-5 until the backlash is within specifications.

Increase backlash.

Tighten adjustingring this side.

Loosen adjustingring this side.

1002795b

Figure 4.39

Decrease backlash.

Loosen adjustingring this side.

Tighen adjustingring this side.

1002796b

Figure 4.40

Measure outer diameter for approximate pitch diameter.

1003090k

Figure 4.37

1003086d

Figure 4.38

Section 4Assembly

- 36 -

Check Gear Set Tooth ContactPatterns (Backlash)Some AxleTech carriers have a generoid hypoid gearset. The tooth contact patterns for each type of gearset are different. Check the part numbers to determine what type of gear set is in the carrier.Refer to Figure 4.41 for the location of part numbers.

ExamplesGeneroid gear sets are identified by K or K2 suffix inthe parts numbers.

• 41272-K or 41272-K2 for the ring gear

• 41723-K or 41723-K2 for the drive pinion

In the following procedures, movement of the contact pattern in the length of the tooth is indicatedas toward the heel or toe of the ring gear. Figure 4.42.

Always check tooth contact patterns on the driveside of the gear teeth. Figure 4.43.

1. Adjust the backlash of a new gear set to either0.012-inch (0.305 mm) or 0.015-inch (0.380 mm)depending on the size of the ring gear. Adjust thebacklash of an old gear set to the setting that youmeasured before the carrier was disassembled.Refer to Ring Gear Backlash Adjustment.

2. Apply a marking compound onto approximately 12gear teeth of the ring gear. Rotate the ring gear sothat the 12 gear teeth are next to the drive pinion.Figure 4.44.

3. Rotate the ring gear forward and backward so that the 12 gear teeth go past the drive pinion sixtimes to get the contact patterns. Repeat if needed to get a clearer pattern.

HEEL

TOE

1003090l

Figure 4.42

PART NUMBER

PART NUMBER

PART NUMBER OPTION

1003089c

Figure 4.41

1001091a

Figure 4.44

DRIVE SIDE, CONVEX 1003091b

Figure 4.43

Section 4Assembly

- 37 -

4. Look at the contact patterns on the ring gearteeth. Compare the patterns to Figures 4.45, 4.46 and 4.47.

The location of good hand-rolled contact patterns fornew conventional and generoid gear sets is towardthe toe of the gear tooth and in the center betweenthe top and bottom of the tooth. Figure 4.45.

When the carrier is operated, a good pattern willextend approximately the full length of the geartooth. The top of the pattern will be near the top of the gear tooth. Figure 4.48.

The location of a good hand-rolled contact patternfor an old gear set must match the wear pattern inthe ring gear. The new contact pattern will be smallerin area than the old wear pattern.

A high contact pattern indicates that the drive pinionwas not installed deep enough into the carrier. A lowcontact pattern indicates that the drive pinion wasinstalled too deep in the carrier.

• If the contact patterns require adjustment:Continue by following Step 5 to move the contact patterns between the top and bottom of the gear teeth.

• If the contact patterns are in the center of thegear teeth: Continue by following Step 6.

5. Change the thickness of the shim pack under thebearing cage to move the contact patternsbetween the top and bottom of the gear teeth.Use the following procedure.

A. Remove the drive pinion and bearing cagefrom the carrier. Refer to Drive Pinion andBearing Cage from the Carrier in Section 2.

1001095a

GOOD PATTERN IN OPERATION, GENEROID GEARS

Figure 4.48

1001093a

HIGH PATTERN, HYPOID GENEROID GEARS

Figure 4.46

1001094a

LOW PATTERN, HYPOID GENEROID GEARS

Figure 4.47

GOOD HAND-ROLLED PATTERN, HYPOID GENEROID

GEARS

1001092c

Figure 4.45

Section 4Assembly

- 38 -

• To correct a high contact pattern: Decrease thethickness of the shim pack under the bearing cage.When decreasing the thickness of the shim pack,the drive pinion will move toward the ring gear.Figure 4.49.

• To correct a low contact pattern: Increase the thickness of shim pack under the bearing cage.When increasing the thickness of the shim pack,the drive pinion will move away from the ring gear.Figure 4.50.

B. Install the drive pinion, bearing cage and shimsinto the carrier. Refer to Shim Pack Thicknessfor a New Drive Pinion in this section.

C. Repeat Steps 2-5 until the contact patterns arein the center between the top and bottom ofthe gear teeth.

6. Adjust backlash of the ring gear within the specification range to move the contact patterns to the correct location in the length of the gearteeth. Loosen one bearing adjusting ring one notchthen tighten the opposite ring the same amount.Refer to Ring Gear Backlash Adjustment.

A. Decrease backlash to move the contact patternstoward the toe of the ring gear teeth. Figure 4.51.

B. Increase backlash to move the contact patternstoward the heel of the ring gear teeth. Figure 4.52.

C. Repeat Steps 2-4 and Step 6 until the contact patterns are at the correct location in the length of the gear teeth.

Decrease shim pack.

1003102b

Figure 4.50

Increase shim pack.

1003101b

Figure 4.49

Move pattern toward toe, loosen adjusting ring

this side.

Decrease backlash.

Tighten adjusting ring.

1003103b

Figure 4.51

Move pattern toward heal,tighten adjusting ring

this side.

Increase backlash.Loosen adjusting ring.

1003104b

Figure 4.52

Section 4Assembly

- 39 -

Decrease shim pack.

Increase shim pack.

7. Install a new allen head M8 capscrew with drylock patch with appropriate tool through the bossof the bearing cage on the plain half case side,until the capscrew is seated between the lugs ofthe adjusting ring. Figure 4.53. Should the originalcapscrew be re-used, a medium strength threadlocker is required to be applied. Refer to the“Torque Table” in section 6.

HDL Inlet Port1. Align hole in piston housing with inlet port hole in

carrier housing. Figure 4.54.

2. Apply oil to O-ring.

3. Install O-Ring into groove in inlet port.

4. Apply 3.0mm bead of sealant STF 02-437 to carrier face around the stem hole.

5. Install inlet port into carrier, sliding its stem intoHDL piston housing. Inlet port should seat flat oncarrier housing w/ minimal gap.

6. Install and hand-tighten inlet port-to-carrier M8 capscrews & washers.

7. Check that inlet port stem is well centered between adjusting ring lugs. If stem contacts lug on oneside, turn adjusting ring slightly to clear.

8. Pull inlet port away from carrier center w/100-200N(22-45 lbf) force.

NOTE: This assures contact between piston housingand adjusting ring.

9. Tighten inlet port-to-carrier M8 capscrews withoutreleasing the pull force, Refer to “Torque Table” inSection 6.

Install And Adjust The Thrust Screw1. Rotate the carrier in the repair stand so the ring

gear faces downward.

2. Apply 1.5mm bead of adhesive sealant STF 02-437 on the first threads.

3. Install the jam nut on the thrust screw, one half thedistance between both ends. Figure 4.55.

4. Install the M22 thrust screw until it contacts thering gear back.

THRUST SCREW

AND JAM NUT

1002806c

Figure 4.55

Figure 4.54

M8 CAPSCREW

WASHER

HYDRAULIC INLET PORT

GROOVEO-RING

ADJUSTINGRING

PISTONHOUSING

Figure 4.53

Section 4Assembly

- 40 -

5. Loosen the thrust screw 1/2 turn, 180 degrees.Clearance between the thrust screw and the ringgear must be 0.025-0.045-inch (0.65-1.14 mm).Figure 4.56.

6. Install the (M22) jam nut to the correct torquevalue against the carrier. Refer to “Torque Table”in Section 6. Figure 4.57.

Hold thrust screwin position.

Tighten jam nut tocorrect torque value.

Figure 4.57

1002807d

Loosen thrust screw

1/2 turn.

Figure 4.56

Section 4Assembly

- 41 -

Hydraulic Differential Lock (HDL)Actuation Function and Leak TestIf axle is equipped with HDL differential, then placeaxle in a safe test stand mounted with carrier inputpinion horizontal for this assembly test. Figure 4.58.

CAUTIONUse only an approved petroleum based hydraulicoil to actuate the hydraulic differential lock (HDL).See Hydraulic Differential Lock Oils in LubricationSection 5.

1. Install a pressure gauge into the HDL inlet port(9/16”-18 UNF) that will clearly read up to 3450kPa (34.5 Bars, 500 psi).

2. Connect hydraulic pressure line with a shut offvalve that will allow a maximum hydraulic pressureof 3,100 kPa (450 P.S.I.) actuation pressure.

3. Actuate the HDL piston 5 cycles.

4. Monitor to check that the piston extends freely andreturns to the initial position when pressure isreleased.

5. Actuate the pressure for another application andlock pressure on. Monitor the pressure gauge tonote a maximum drop allowed of 150kPa (1.5 Bar,22 psi) after 1 minute applied. If value noted isgreater, the Carrier must be removed and the reason for the larger pressure drop determined.Reference AxleTech Carrier manual #5.4 for cor-rect additional carrier disassembly procedures.

6. Remove the pressure gauge from the HDLinlet port.

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Figure 4.58

HDL INLET PORT

LubricationBreather

CAUTIONCover the breather when steam cleaning the axlehousing to prevent water from entering the axle housing and contaminating the oil. Damage to components will result. Breathers releasepressure and vacuum condensation to help maximize oil and component life.

Seals

CAUTIONAlways use the correct tools and procedureswhen replacing seals to prevent incorrect installation and leaking seals. Seals keep lubrication in and dirt out of a component.When they are worn or damaged, seals leak and produce damaging low lubricant levels thatwill damage components.

Oil LevelCheck and Adjust:Correct procedure to check oil level in the axle assembly:

1. Park the vehicle on a level surface. Place blocksin front and back of the rear axle wheels to keepthe vehicle from moving.

2. Clean the area around the fill plug in the axlehousing. Remove the plug from the axle housingassembly. The oil level must be level with the bottom of the fill plug hole.

• If the oil flows from the hole when you loosenthe plug: the oil level is too high. Drain the oiltoo the correct level.

NOTE: Follow the vehicle manufacturer’s recommendation of disposal of the oil drained from the axle housing assembly to assure disposal is in an environmentally friendly procedure.

NOTE: Oil level too high may cause damage to theseals and other components. It is essential the correct oil level be maintained for component damage not to occur.

• If the oil level is below the bottom of the fill plug:Add the specified oil according to the followingprocedure: Fill the axle housing assembly withthe specified oil through the fill plug hole. Wait afew minutes to allow the oil to flow through theentire axle housing assembly. Check the oil leveland fill to the correct level, if necessary.

NOTE: Too low an oil level could cause componentdamage as proper lubrication may not be available

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to protect against component damage.

3. Install and tighten the fill plug to the correct torquespecification. Refer to “Torque Table” in Section 6.

Approved Oil ListingsSpecific oils other than those listed should haveapproval prior use in this assembly as damage mayoccur to components in axle assembly. ReferenceAxleTech International oil and grease base specifications STC05-000 for descriptions of oils andSTC 05-200 for greases that meet the AxleTech specifications and approved criterion. These specificationsincludes the use of Petroleum, Semi-Synthetic andFull Synthetic oils. This specification should bereviewed when questions relating to Oil Compatibility,use of Synthetic oils, and seal compatibility are beingconsidered. See attached chart for recommendedlubricant cross reference (Viscosity) and TemperatureChart to provide recommendations of oil viscositiesrecommended based on ambient temperature rangein vehicle service.

Approved GreaseRecommendations for Axle TrunnionAssemblyGrease: Multipurpose Grease (1)

Specification: Per AxleTech International greasespecification STC 05 201 (NLGI Grade 1) for Lithium12 Hydroxy Stearate or Lithium Complex.

(1) AxleTech recognizes that industry trends are mov-ing towards selection and usage of synthetic basedgreases in vehicle maintenance. However, someseals are known to expand when in contact with syn-thetic grease. The original assembly has been donewith above recommended grease used and recom-mendation is to continue with similar grease in serv-ice.

Off-Highway Operation Intervals*

Recommended Check Petroleum Initial Oil ChangeOil Level Oil Change 50-100 Operating hrs. for initialoil change.

Check oil every 200-250 Operating hrs.

Typical 1,000 hrs. or twice a year, whichever comes first*

Hydraulic Differential Lock OilsHydraulic differential actuation oils should complywith the “Anti-Wear”Hydraulic Oil for Mobile andIndustrial Equipment and per ISO 68 (Summer) andISO 22 (Winter). Passes the ASTM D665A & D665BRust tests. Recommended fluids should be foamresistant (containing a foam inhibitor). Fluids shouldbe hydrolytically stable and demulsify water (not hold water in suspension).

NOTE: Recommended change intervals are same as for carrier/axle assembly lubricants.

Section 5Lubrication

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Carrier assemblies with a hypoid gear set requireextreme pressure EP type lubricant in the GL5 oilclassification.

Approved lubricants for AxleTech carriers with hypoidgearsets would include currently listed petroleumbased, synthetic based or synthetic blend gear oilsmeeting SAE J2360 Gear Lubricating OilSpecification as evidenced by being included on thecurrent Lubricant Review Institute (LRI) QualifiedProducts List, or previously approved by AxleTechpetroleum based extreme pressure gear lubricantoils, previously known as API rated GL-5 gear oils.

Lubricant Specification Table: Viscosity and to Outside Temperature Chart

Lubricant Minimum Outside Maximum OutsideSpecification Description Cross Reference Temperature Temperature

STC 05-001 Hypoid Gear Oil GL-5, S.A.E. 85W/140 +10°F (–12.2°C) - - -*

STC 05-002 Hypoid Gear Oil GL-5, S.A.E. 80W/140 –15°F (–26.1°C) - - -*

STC 05-003 Hypoid Gear Oil GL-5, S.A.E. 80W/90 –15°F (–26.1°C) - - -*

STC 05-004 Hypoid Gear Oil GL-5, S.A.E. 75W/90 –40°F (–40°C) - - -*

STC 05-005 Hypoid Gear Oil GL-5, S.A.E. 75W –40°F (–40°C) +35°F (+1.6°C)

STC 05-006 Hypoid Gear Oil GL-5, S.A.E. 75W/140 –40°F (–40°C) - - -*

*There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed250°F (+121°C).

Section 5Lubrication

- 43 -

As sump temperatures exceed 250°F (121°C), theoxidation rate of the oil increases rapidly. Syntheticbased oils have been shown to offer a 50°F higheroperating temperature advantage and up to a fivefold increase in sump life, exhibiting degradationrates at 325°F (190°C) that are similar to petroleumbased oils at 275°F (135°C). However, the advantagesof synthetic based oils are minimal at sump temperatures below 250°F (121°C). Operating conditions that result in sump temperatures in excess of 250°F (121°C) should be investigated and corrected immediately as the oil life, bearing and gear contact fatigue lives and bending fatiguedurability are all at risk.

Torque Values For FastenersGeneral Information1. If you do not know the size of the fastener that is

being installed, measure the fastener. Use the following procedure.

American Standard Fasteners

A. Measure the diameter of the threads in inches,dimension X. Figure 6.1.

B. Count the amount of threads in 1-inch. Figure 6.1.

ExampleAmerican Standard size fastener is 0.50-13.

• 0.50 is the diameter of the fastener in inches or dimension X.

• 13 is the amount of threads in 1-inch.

Metric Fasteners

A. Measure the diameter of the threads in millimeters (mm), dimension X. Figure 6.2.

B. Measure the distance of 10 threads, point to pointin millimeters (mm), dimension Y. Make a note ofdimension Y. Figure 6.2.

C. Divide dimension Y by 10. The result will be thedistance between two threads or pitch.

Example• Metric size fastener is M8 x 1.25.

• M8 is the diameter of the fastener in millimeters(mm) or dimension X.

• 1.25 is the distance between two threads or pitch.

2. Compare the size of fastener measured in Step 1to the list of fasteners in Table E to find the correcttorque value.

AMOUNT OF THREADS

IN 1"1"

X

1003113aX DIMENSION = (EXAMPLE 1/2")

Figure 6.1

X

Y

1003114b

PITCH

X DIMENSION = (EXAMPLE M8 OR 8 MM) Y DIMENSION = DISTANCE OF 10 THREADS

Figure 6.2

Section 6Torque

- 44 -

SIZE / SPEC TYPE LOCATION TORQUE N.m (lb-ft) THREAD[1] Nominal Range COMPOUND

M8 X 1.25 capscrew L25 HDL: Inlet port, 38.3 (28) 33.5-43.1 (25-32) Medium strengthSocket-head Carrier hsg

capscrew L30 Carrier: Bearing Cap 33 (24) 28-38 (21-28) Dry patchSocket-head (adj. ring lock) Q-29 Pre-Applied

or Medium strength

M12 X 1.75 capscrew L45 Carrier: Pinion Cage- 132 (97) 119-145 (88-107) Medium strengthhex-head Carrier hsg

capscrew L70 Carrier: Diff Case- 143 (105.5) 130-155 (96-114) Loctite® 680TM

hex-head Diff Case

M16 X 2 capscrew L50 Carrier: Carrier Hsg- 328 (242) 295-361 (218-266) High strengthhex-head Axle Hsg

capscrew L65 Carrier: Carrier Hsg- 328 (242) 295-361 (218-266) High strengthhex-head Axle Hsg

M16 X 1.5 capscrew L62 Carrier: Hypoid Gear- 350 (258) 315-385 (232-284) Medium strengthSocket-head Diff Case

M20 X 2.5 capscrew L120 Carrier: Bearing Cap- 485.0 (358) 430-540 (317-398) Oilhex-head Carrier Hsg

M22 x 1.5 jam nut Carrier: Hypoid Gear 204.0 (151) 136-272 (100-201) NoneThrust Screw

M39 x 1.5 nut Carrier: Yoke- 1393 (1028) 1250-1535 (922-1132) OilHypoid Pinion

TORQUE TABLE

Approved thread locking compoundsGasket eliminator® 518 flange sealantMedium strength : Loctite® # 241 / 242 / 243, ThreeBond# 1334High strength : Loctite® # 271 / 273, ThreeBond# 1305

Section 6Torque

- 45 -

- 46 -

Section 7Adjustments and Specifications

Drive Pinion Bearings — Preload (Refer to Section 4)

Specification New bearings15-25 lb-in (1.7-2.8 N•m)Used bearings5-25 lb-in (0.56-2.8 N•m)

Adjustment Preload is controlled by the thickness of the spacer between bearings.To increase preload, install a thinner spacer.To decrease preload, install a thicker spacer.

Drive Pinion — Depth in Carrier (Refer to Section 4)

Specification Install the correct amount of shims between the bearing cage and carrier. To calculate, use old shim pack thickness and new and old pinion cone numbers.

Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.

Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled) (Refer to Section 4)

Specification Conventional gear setToward the toe of the gear tooth and in the center between the top and bottom of the toothGeneroid gear setBetween the center and toe of the tooth and in the center between the top and bottom of the tooth

Adjustment Tooth contact patterns are controlled by the thickness of the shim pack between the pinion bearing cage and carrier and by ring gear backlash.To move the contact pattern lower, decrease the thickness of the shim pack under the pinionbearing cage.To move the contact pattern higher, increase the thickness of the shim pack under the pinionbearing cage.To move the contact pattern toward the toe of the tooth, decrease backlash of the ring gear.To move the contact pattern toward the heal of the tooth, increase backlash of the ring gear.

Main Differential Bearings — Preload (Refer to Section 4)

Specification 15-35 lb-in (1.7-3.9 N•m)orExpansion between bearing capsRS-145 and RS-160 carrier models — 0.002-0.009-inch (0.05-0.229 mm)

Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached

Main Hydraulic Differential Lock Gears — Rotating Resistance (Refer to Section 4)

Specification 74-162 lb-ft (100-220 N•m) torque applied to one side gear.

Ring Gear — Backlash (Refer to Section 4)

Specification Ring gears that have a pitch diameter of less than 17-inches (431.8mm).Range: 0.008-0.018-inch (0.20-0.46 mm)

0.012-inch (0.30 mm) for a new gear setAdjustment Backlash is controlled by the position of the ring gear. Change backlash within specifications

to get a good tooth contact pattern.To increase backlash, move the ring gear away from the drive pinion.To decrease backlash, move the ring gear toward the drive pinion.

Ring Gear — Runout (Refer to Section 4)

Specification 0.008-inch (0.20 mm) maximum.

WARNING

Wear safe clothing and eye protection when youuse welding equipment. Welding equipment canburn you and cause serious personal injury.Follow the operating instructions and safety pro-cedures recommended by the welding equipmentmanufacturer.3. To make the box section, cut and weld 1.0-inch x

2.0-inch mild steel square stock according todimensions C and D. Figure 7.3.

4. Cut a 4.0-foot x 1.25-inch piece of mild steelround stock to make the yoke bar handle. Centerweld this piece to the box section. Figure 7.3.

• To increase yoke bar rigidity: Weld two anglepieces onto the handle. Figure 7.3.

Unitized Pinion Seals And SealDriversRefer to Table B and Figure 7.4 for information onunitized pinion seals and seal drivers.

!How To Make A Yoke Bar or Flange Bar1. Measure dimensions A and B of the yoke you are

servicing. Figure 7.1.

2. Measure the hole spacing of the 4 holes in thetapped yoke as shown in Figure 7.1.

3. Calculate dimensions C and D of the yoke bar byadding 0.125-0.250-inch to dimensions A and Bof the yoke. Figure 7.2.

WARNINGWear safe clothing and eye protection when youuse welding equipment. Welding equipment canburn you and cause serious personal injury.Follow the operating instructions and safety procedures recommended by the weldingequipment manufacturer.

4. Using the hole dimensions measured on the inputyoke, cut a rectangular plate to fit in the box sec-tion of the yoke bar with the 4 holes drilledthrough the plate with same hole size as requiredfor the driveline attaching screws.

5. Cut a 4.0-foot x 1.25-inch piece of mild steelround stock to make the yoke bar handle. Centerweld this piece to the box section. Figure 7.2.

• To increase yoke bar rigidity: Weld two anglepieces onto the handle. Figure 7.2.

!

Figure 7.1

A

B

YOKEBAR

Figure 7.2

SEALDRIVER

SEALDRIVER

R4422401

Figure 7.4

Section 8Special Tools

- 47 -

Figure 7.3

Inspection Tool1. Make an inspection tool using an axle shaft that

matches the spline size of the differential sidegear. Cut the shaft to approximately 12-inches(304.8 mm). Weld a nut onto the end of the shaft. Figure 7.5.

Unitized Yoke Seal DiameterPinion Seal Seal Installation Location Seal Driver Inches (mm)

A-1205-N-2588 RS-145 Carrier Input - R4422401 3.000 (76.2)Single Reduction 3.005 (76.33)Differential Carriers

To obtain seal driver KIT 4454, call 1-877-547-3907.

Unitized Pinion Seals And Seal Drivers

1003071a

APPROXIMATELY 304.8 MM (12-INCHES)

SIDE VIEWWELD NUT

TO END OF SHAFT

END VIEW

Figure 7.5


- 48 -

Figure 7.6TOOL 1

25ø75

TRUNNION SEAL INSTALLATION CARRIER BEARING CAGE

ø160

Figure 7.7TOOL 2

75

TRUNNION BEARING CAGE PINION YOKE SEAL INSTALLATION

ø127

ø136

1 x 45°

1. Plates 8’ long x 3/4” thick x 1-1/4” wide with a tongue to fit slot in bar weld plates to bar2. Handle 7” long with slot in one end to fit clamp screw3. Bar 2” diameter x 9” long with one end slotted to fit plate4. Weld all around after pressing plug in pipe5. Weld6. Shape and size of holes to fit carrier7. 23-1/2” Center to center of pipe8. Chamfer end of pipe for weld9. 4” diameter pipe10. Plug 4” diameter x 7” long with one end turned 3” long to fit pipe. Drill 2” hole and mill

3/16” wide slot 2” form top11. Screw 3-1/2” long x 5/8” diameter with flats on end to fit handle and 2-1/2” length of thread

on other end12. Drill 3/8” Hole through handle and screw

2

1

4

3

6

5

8

7

10

9

12

11

SPX Kent-Moore

part number J-3409-D

1002990e

Center Assembly Stand

Figure 7.8


- 49 -

Notes

- 50 -

Notes

- 51 -

- 54 -

Notes

Suite 400 AxleTech International France AxleTech do Brasil Sistemas Automotivos Ltda.3001 West Big Beaver Road 4, Rue Jean Servanton Avendia Joao Batista, 830Troy, Michigan 48084 Boite Postale 656 Centro-Osasco-SPU.S.A. 42042 Saint Etienne Cédex 1 06097095 BrasilToll Free: 877-877-9717 France Phone: +55 11 36846641Non-Toll Free: 248-816-5401 (33) 477.92.88.00 Fax: +55 11 36846859Fax: 248-435-1990 Fax: (33) 477.92.88.93Website: www.axletech.com

MM5.4 © Copyright AxleTech InternationalIssued 10-06 Printed in the USA

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