Differential & Bevel Gear

Usage:

Remove Differential & Bevel Gear

Start By:

a. remove transmission

b. remove final drives

1. Remove two sun gear shafts (1) from the differential.

2. Disconnect wire connector (4).

3. Remove two bolts (2) and their washers from differential lock valve (6). Remove differential
lock valve (6) from the differential.

4. Remove two bolts and clips (7) from the differential. Remove hose (8) from the differential.

5. Remove drive shaft yoke (5) from the differential.

6. Disconnect hose assembly (3) from the differential.

Tooling Option 1

7. Remove two nuts and washers (11) from the differential flange. Install Tooling (A), as shown.
Use three 5/8 in - 18 Bolts (9) in order to secure Tooling (A) to the differential.

8. Remove ten nuts and washers (10) from the differential flange.

9. Remove differential and bevel gear (12) from the case and frame. The weight of differential
and bevel gear (12) is 204 kg (450 lb).

Tooling Option 2

NOTE: The tool in the photo is a proto-type. The new design tool will look different, but it will
work in the same manner.

10. Install Tool (B) over the pinion shaft, as shown.

11. Remove ten nuts and washers (11) from the differential flange.

12. Remove differential and bevel gear (12) from the case and frame. The weight of differential
and bevel gear is 204 kg (450 lb).
Install Differential & Bevel Gear

1. Make sure that all components of differential and bevel gear (12), and the components of the
case and frame are clean prior to installing differential and bevel gear (12). During the
installation check the condition of all O-ring seals used any hose assemblies that were
disconnected. If any of the seals are damaged, use new parts for replacement.

2. Use Tool (B) in order to position differential and bevel gear (12) to their original location in
the case and frame. Install ten nuts and washers (10) in the differential flange. Tool (A) can also
be used to complete this step. See Step 3.

3. Use Tool (A) in order to position differential and bevel gear (12) to their original location in
the case and frame. Install ten nuts and washers (10) in the differential flange. Remove Tooling
(A) from the differential. Install two nuts and washers (11) to the differential flange.
4. Connect hose assembly (3) to the differential.

5. Install drive shaft yoke (5) to the differential

6. Position hose (8) to the differential. Install two bolts and clips (7) to the differential.

7. Position differential lock valve (6) to the differential. Install two bolts and washers (2) in
differential lock valve (6).

8. Connect wire connector (4).

9. Install two sun gear (1) in the differential.

End By:

a. install final drives

b. install transmission

Disassemble Differential & Bevel Gear

Start By:
a. remove differential and bevel gear

1. Attach a lifting sling and a hoist to differential group (4). Remove four bolts and washers (2)
from carrier assembly caps (1).

2. Remove carrier assembly caps (1) and locks (5) from carrier assembly (3). Note that the
locknut and the bearing cup on the ring gear side will stay in carrier assembly (3) when carrier
assembly cap (1) is removed. Remove this locknut and bearing cup.

3. Remove differential group (4) from carrier assembly (3).

4. Remove cage assembly (6) from differential group (4).

5. Remove two seals (8) from cage assembly (6).

6. Remove retaining ring (9) from cage assembly (6).

7. Remove nut (10) from cage assembly (6).

8. Remove bearing cup (7) from cage assembly (6).

9. Remove 12 bolts and washers (11) from housing assembly (12).

10. Install two 1/2 in - 13 Forcing Screws (14) and tighten evenly in order to loosen housing
assembly (12).

11. Remove housing assembly (12) from differential group (4).

12. Remove bearing cone (13) from differential group (4).

13. Remove bronze washer (15) from differential group (4).

14. Remove piston (16) with the two seals from differential group (4).
15. Remove inner seal (17) and outer seal (18) from piston (16).

16. Remove gear (19) and clutch assembly (20) from differential group (4).

17. Remove eight plates (21) and seven friction disc (22) from gear (19).

18. Remove disc (23) from gear (19).

19. Remove nine bolts (24) and the washers from housing (25).
20. Install two 1/2 in - 13 Eyebolts (26) in gear (27). Attach chains and a hoist to eyebolts (26).
Remove housing (25) and gear (27) from housing (28). The weight of housing (25) and gear (27)
is 52 kg (115 lb).

21. Remove 24 bolts (29) and the washers that hold gear (27) to housing (25). Remove gear (27)
from housing (25). The weight of gear (27) is 41 kg (90 lb).

22. Remove bearing cone (30) from housing (25).

23. Remove bronze washer (31) and gear (32) from spider assembly (33).
24. Remove spider assembly (33) from housing (34).

25. Remove three spacers (35) and three gears (36) from spider assembly (33).

26. Remove three bearings (37) from three gears (36).

27. Note the location of the hydraulic fitting on retainer (39) for assembly purposes. Remove six
bolts and washers (38) from retainer (39). Remove retainer (39) and the gasket from housing
(40).
28. Remove lip seal (41) from retainer (39). Note the direction that the sealing lip is facing, for
assembly purposes.

29. Remove six bolts and the washers (42) from housing (40).

30. Install two 1/2 in - 13 Forcing Screws (43) in housing (40). Use forcing screws (43) to
loosen housing (40) from carrier (45).

31. Remove housing (40), the shim pack and pinion assembly (44) from carrier (45).

32. Bend the tab on nut lock washer (46) in order to release nut (45).

33. Remove bearing locknut (45), nut lock washer (46) and washer (47) from pinion assembly
(44).
34. Press pinion assembly (44) from housing (40).

35. Remove bearing cone (48) from pinion assembly (44).

36. Remove bearing cone (49) from pinion assembly (44).

37. Remove two bearing cups (50) from housing (40).

Assemble Differential & Bevel Gear

NOTE: It is imperative that all power train parts be clean and free of rust before and during
assembly. Parts suspected of poor quality should be verified for conformance before using.
NOTE: Do not use preheating of bearing cones or precooling of bearing cups when you
assemble the differential and bevel gear unit in a shop. Use a suitable power press to install the
cones on shafts and cups in housing bores.

NOTE: Preheating or precooling of bearing cones or cups may be used to aid assembly where a
power press is not available. Limit the heating of the cones to 135° C (275° F) for no more than
one hour. It is important to reseat the cone or the cup with a suitable driver after the bearing cone
or cup and adjacent parts have reached a uniform temperature.

1. During assembly check the condition of all seals and gaskets used in the differential and bevel
gear. If any of the seals or gaskets are damaged, use new parts for replacement.

2. Lower the temperature of two bearing cups (50). Install two bearing cups (50) inn housing
(40). Use a 0.05 mm (.002 in) Feeler Gage in order to check for full seating of the cup face
against the housing shoulder.

3. Install bearing cone (49) on pinion shaft (44). Use a 0.05 mm (.002 in) Feeler Gage in order
to check for full seating of the cone face against the shaft shoulder. Lubricate the bearing with
6V-4876 Lubricant.

Installing Heated Bearing

4. Install housing (40) on pinion assembly (44).

5. Lubricate bearing cup (50) or bearing cone (48) with 6V-4876 Lubricant. Install bearing cone
(48) on pinion assembly (44). Install bearing cone (48) with end play remaining in bearings (48)
and (49).

6. Install washer (47), nut lock washer (46) and bearing locknut (45) on pinion assembly (44).
Secure pinion assembly (44) and tighten bearing locknut (45). Rotate housing (40) as you tighten
bearing locknut (45). It may be necessary to strike pinion shaft (44) and housing (40) in order to
make sure the bearing moves on pinion shaft (44).

7. Tighten bearing locknut (45) to a rolling torque of 0.9 to 1.1 N·m (7.9 to 9.7 lb in) Do not
exceed the specified torque. Secure bearing locknut (45) by bending the tab on nut lock washer
(46) in the closest retaining key slot in bearing locknut (45). Check the assembly to ensure zero
end play.

NOTE: Use only 80% of the full shim pack at this time.

8. Position housing (40), 80% of the shim pack and pinion assembly (44) to carrier (45). Install
six bolts and washers (42) secure housing (40) to carrier (45). Tighten bolts (42) to a torque of
135 ± 15 N·m (99 ± 11 lb ft).
9. Install lip seal (41) in retainer (39). The sealing lip must face inward. Lubricate the sealing lip
with SAE 30 Weight Oil.

10. Position retainer (39) and the gasket on housing (40). Face the hydraulic fitting that is on
retainer (39) to its original location. Install six bolts (38) to secure retainer (39) to housing (40).

11. Install bearing (37) in gear (36). The bearing (37) should be flush with the face on the back
of gear (36). Repeat this step on two remaining gears.

12. Lubricate the shafts of spider (33) with 6V-4876 Lubricant. Install three spacers (35) and
three gears (36) on spider assembly (33).
13. Install spider assembly (33) in housing (34).

14. Install bronze washer (31) and gear (32) on spider assembly (33). Note that the slots located
on washer (31) must align with the dowel pins in housing (25). Housing (25) will be installed on
the assembly during step (16).

15. Position housing (25) on gear (27). The weight of gear (27) is 41 kg (90 lb).

16. Install 24 bolts (29) and the washers that holds gear (27) to housing (25). Tighten bolts (29)
to a torque of 270 ± 25 N·m (200 ± 18 lb ft).

17. Install bearing cone (30) on housing (25). Use a 0.05 mm (.002 in) Feeler Gage in order to
check for full seating of the cone face to the housing shaft shoulder.
18. Install two 1/2 in - 13 Eyebolts (26) in gear (27). Attach chains and a hoist to eyebolts (26).
Position housing (25) and gear (27) on housing (28). The weight of housing (25) and gear (27) is
52 kg (115 lb). Make sure that the dowel pins on the bottom of housing (25) and gear (27) align
with the slots in washer (30). Refer to Step 14.

19. Remove eyebolts (26) from the assembly. Install nine bolts (24) and the washers in order to
secure the gear and housing assembly to housing (28).

20. Install disc (23) on gear (19).

21. Install eight disc (21) and seven friction disc (22) on gear (19), beginning with disc (21).
Lubricate both sides of friction disc (22) with a SAE 30 Weight Oil
22. Turn differential group (4) over by 180 degrees. Install gear (19) and clutch assembly (20) in
differential group (4).

23. Install inner seal (17) and outer seal (18) on piston (16). Lubricate seals (17) and (18) and the
bore of piston (16) with clean SAE 30 Weight Oil.

24. Install piston (16) in differential group (4).

Housing (12) Showing Dowel Pins in Alignment with Slots in Washer

25. Install bronze washer (15) in differential group (4). Note that the slots in washer (15) must
align with the dowel pins on housing assembly (12) during assembly Step 24.
26. Install housing assembly (12) on differential group (4). Make sure that dowel pins align with
the slots in bronze washer (15).

27. Install 12 bolts and washers (11) in order to secure housing assembly (12) to differential
group (4). Tighten the bolts to a torque of 135 ± 15 N·m (99 ± 11 lb ft). Turn the unit over and
tighten bolts (24) to a torque of 135 ± 15 N·m (99 ± 11 lb ft).

28. Install bearing cone (13) on housing assembly (12). Use a 0.05 mm (.002 in) Feeler Gage in
order to check for full seating of the cone face to the housing shaft shoulder.

29. Install two seals (8) on cage assembly (6).

30. Install retaining ring (9) on cage assembly (6).

31. Install bearing cup (7) in cage assembly (6).

32. Install nut (10) in cage assembly (6). Leave nut (10) loose for later backlash adjustments.
Make sure that nut (10) turns freely and is not cross threaded.

33. Lubricate cage assembly (6) with 6V-4876 Lubricant. Install cage assembly (6) on the
bearing cone and in differential group (4).

34. Attach a lifting sling and a hoist to differential group (4). Lubricate bearing cone (30) with
6V-4876 Lubricant. Install the bearing cup that was removed from the ring gear side of carrier
assembly cap (1) on bearing cone (30).

35. Position differential group (4) to carrier assembly (3). Position caps (1) to the assembly.
Install four bolts (2) and the washers in order to secure caps (1) to carrier assembly (3). Tighten
bolts (2) to a torque of 100 N·m (74 lb ft). Make sure that you do not bind the differential in the
carrier assembly caps.

36. Install the locknut in the assembly cap on the bevel gear side of the assembly. Make sure that
the adjusting nut turns freely and is not cross threaded.
37. Use an 8T-5096 Dial Indicator Group for adjusting the backlash. Tighten adjusting nut (51)
while you rotate bevel gear (27). Advance adjusting nut (51) to a zero backlash position. Back
adjusting nut (51) off to the nearest lock position. The maximum back off movement is one lug
on the adjusting nut (51).

38. Advance adjusting nut (52) to take up end play. Apply torque pressure to adjusting nut (52)
to assure that the bearing cones and the bearing caps are seated. Release the tension from
adjusting nut (52). Finger tighten adjusting nut (52) to remove end play from the assembly.

39. Adjust adjusting nut (51) to give backlash of the bevel gear and the pinion of 0.25 ± 0.05 mm
(.010 ± .002 in). While you keep adjusting nut (52) adjusted to take up end play.

40. Tighten adjusting nut (52) to preload the bearings. Use a dial indicator to ensure that the
bearing cone moves 0.3 ± .05 mm (.012 ± .002 in). After adjusting nut (52), check the rolling
torque of the installed pinion to assure that it is written 1.4 - 2.0 N·m (12 - 18 lb ft).

NOTE: The specified rolling torque is for new pinion bearings. Used bearings should have a
rolling torque of 0.7 - 1.0 N·m (6 - 9 lb ft).

41. After the gear clearance (backlash) and bearing preload adjustments have been made, check
the tooth contact setting between the bevel gear and pinion as follows:

a. Put a small amount of marking compound (Prussian blue) on the bevel gear teeth. Turn the
pinion in both directions, and check the marks made on the bevel gear teeth.
Correct Tooth Contact Setting

b. With no load, the correct tooth contact setting will be as shown. The correct area of tooth
contact is located equally on both sides and starts near the toe of the gear and goes 30% to 50%
up the length of the tooth. With this setting, when a load is put on the gear, the load will be over
the correct area of the teeth.

Short Toe Contact Setting

c. If the pinion shaft is too far away from the bevel gear, short toe contact will be the result as
shown. The teeth of the pinion will be in contact with the toe ends of the convex faces (part that
makes a curve toward the outside), and the top edge of the heel end of the concave faces (part
that makes a curve toward the inside). To correct this, remove shims from behind the inner
pinion bearing. After this is done, check the gear clearance (backlash) and tooth contact again.
Short Heel Contact Setting

d. If the pinion shaft is too near to the center of the bevel gear, short heel contact will be the
result as shown. The teeth of the pinion will be in contact with the toe ends of the concave faces
(part that makes a curve toward the inside), and the heel ends of the convex faces (part that
makes a curve toward the outside). To correct this, add shims behind the inner pinion bearing
race. After this is done, check the gear clearance (backlash) and tooth contact again.

NOTE: Several adjustments of both pinion and bevel gear may be needed before correct tooth
contact and gear clearance (backlash) is made. Always remember that a change to gear clearance
(backlash) will also change the tooth contact. Therefore, be sure gear clearance (backlash) is in
correct adjustment before tooth contact is checked.

e. After gear clearance (backlash) and tooth contact are correct, remove the extra marking
compound (Prussian blue) from the bevel gear and pinion.

42. Tighten the bevel gear main cap bolts (2) to a final torque of 370 ± 50 N·m (273 ± 36 lb ft).

43. Perform a final measurement of the backlash to ensure that it is within specifications
established in Step 39.