Inspect and Reassemble

Differential Assembly

Service Repair No - 51.15.07 (cont.)

Inspect

1. Clean and inspect all components for wear and damage.
2. Fit planet gears and rotate to align cross shaft holes.
3. Fit cross shaft, ensure roll pin hole is aligned.
4. Secure cross shaft with new roll pin.
5. Fit crown wheel to carrier, fit new bolts and tighten to 60 Nm (44 ft. lbs.).





6. Ensure original head bearing shim is clean and free from burrs and fit under bearing race.
7. Ensure pinion bearing cup recesses are clean and free of burrs and using LRT-51-018-4 fit pinion head and tail bearing races.
8. Fit pinion head bearing to pinion.
9. Lubricate bearings with thin oil.
10. Ensure original tail bearing shim is clean and free from burrs and fit under bearing race.
11. Fit pinion and pinion tail bearing.
12. Fit pinion flange, washer and bolt.
13. Use LRT-51-003 to restrain pinion flange.
14. Tighten pinion flange bolt to 100 Nm (74 ft. lbs.).
15. Check pinion for end float. Should read zero.





16. Rotate pinion several times to settle bearings, check pinion Torque to Turn. Torque to Turn should be recorded during pinion rotation. Pinion Torque to Turn should be 4 to 6 Nm (3 to 4.5 ft. lbs.).
17. Adjust size of tail bearing shim to obtain correct pinion Torque to Turn (0.025 mm = 1 Nm (0.001 = 0.7 ft. lbs.) approximately).
18. Position LRT-51-018-7 on surface plate, establish zero and reference DTI.





19. Ensure pinion height setting block, setting gauge and mating faces are clean and free from burrs.
20. Locate setting block LRT-51-018-1 over pinion head, ensure it is fully seated in position.





21. Pinion height setting procedure:
'A'= Nominal pinion height setting, 74.390.0
'B'= Setting block height.
'C'= Head height setting.
'C'='A'-'B'. Subtract nominal pinion height 'A' from setting block height 'B' (on side of setting block).
Example: 74.390 - 73.130 = 1.26 mm (2.929' - 2.88' = 0.049'). Therefore pinion head height reading is 1.260 mm ± 0.025 mm (0.049' ± 0.001').

CAUTION: Setting block height must be checked using figures on side of block.





22. Align setting gauge LRT-51-018-7 to setting block, rock gauge to obtain minimum reading. If reading is lower than required reading, decrease shim size. If reading is higher than required reading, increase shim size.
23. Using LRT-51-003 to restrain pinion flange, remove bolt and washer. Remove pinion flange.
24. Remove pinion, collect tail bearing and tail bearing shim.
25. Remove pinion head bearing outer race and shim. Discard shim. Ensure bearing race recess is clean and free from burrs.
26. Fit calculated shim, and using LRT-51-018-4 fit head bearing outer race.
27. Fit pinion, pinion tail bearing and tail bearing shim.
28. Fit pinion flange and bolt and washer. Using LRT-51-003 to restrain pinion flange, tighten bolt to 100 Nm (74 ft. lbs.).
29. Rotate pinion in both directions to settle bearings.
30. Recheck pinion Torque to Turn, adjust if necessary.
31. Recheck pinion head height.
32. Using LRT-51-003 to restrain pinion flange, remove bolt and washer. Remove pinion flange.
33. Discard bolt.





34. Using LRT-51 -010 fit pinion seal.
35. Ensure spacer and tail bearing are correctly located.
36. Fit pinion, pinion flange and washer.
37. Fit new pinion flange bolt and tighten to 100 Nm (74 ft. lbs.).
38. Lightly oil differential bearings.
39. Ensure spring dowels are fitted in bearing caps.
40. Fit differential bearing outer races and locate differential assembly into housing.
41. Fit bearing caps and tighten bolts to 10 Nm (7.5 ft. lbs.).





42. Fit adjusting nuts, tighten crown wheel side nut to 22 Nm (16 ft. lbs.). Ensure opposing nut is loose.
43. Position DTI to check crown wheel backlash. Adjust opposing nut to obtain correct crown wheel backlash.
44. Rotate pinion in both directions to settle bearings.
45. Measure in 3 places to obtain correct crown wheel backlash.

NOTE: Crown wheel backlash should be within 0.076 mm - 0.177 mm (0.003' - 0.007').

46. Align adjusting nuts to next roll pin slot, do not loosen nuts to align slots.
47. Tighten bearing cap bolts to 90 Nm (66.5 ft. lbs.).
48. Secure adjusting nuts with new roll pins.





49. Apply Prussian Blue to crown wheel teeth to check tooth contact.
50. Rotate pinion several times to obtain full tooth contact.
51. A = Normal pattern, the drive pattern should be centered on the gear teeth. The coast pattern should be centered on the gear teeth but may be towards the toe. There should be some clearance between the pattern and the top of the gear teeth.
52. B = Backlash correct, thinner pinion shim required.
53. C = Backlash correct, thicker pinion shim required.
54. D = Pinion shim correct, decrease backlash.
55. E = Pinion shim correct, increase backlash.
56. Note assembly Torque to Turn when checking tooth contact. Total Torque to Turn should not exceed 10.85 Nm (8 ft. lbs.).

Reassembly

1. Fit differential assembly.