Assemble Front Differential

ASSEMBLE FRONT DIFFERENTIAL

CAUTION:
Do not clean or lubricate the new pinion shaft tail bearing, as it is supplied coated with a low friction oil.

Failure to follow this instruction will require the pinion shaft tail bearing to be replaced before the differential can be successfully assembled.

Ensure adequate support plates are placed between special tool 208-890 and press. Failure to follow this instruction may cause damage to the special tool.





1. Using special tool 205-896, install a new pinion shaft tail bearing cup and apply a press load of 2 to 5 tons, until the bearing cup is fully installed. (Figure 23)

CAUTION:
Do not clean or lubricate the new pinion shaft tail bearing, as it is supplied coated with a low friction oil. Failure to follow this instruction will require the pinion shaft tail bearing to be replaced before the differential can be successfully assembled.





2. Install the new pinion shaft tail bearing. (Figure 24)

CAUTION:
Do not lubricate the pinion seal.





3. Using special tool 205-892, install the new pinion seal. (Figure 25)





4. Position special tool 205-890 in a suitable vice (Figure 26).





5. Install the new collapsible spacer (Figure 27).

6. Lubricate the existing pinion shaft head bearing with a light coating of differential oil.

CAUTION:
Ensure the special tool is correctly aligned. Failure to follow this instruction may result in damage to the pinion seal.





7. Using special 205-892 tool, install the pinion shaft assembly (Figure 28).

NOTE:
The pinion flange may be a tight fit on the pinion shaft splines. If the pinion flange is tight, support the pinion shaft and seat the pinion flange with a soft-face hammer.





8. Install the new pinion flange (Figure 29).

CAUTION:
Ensure the specified torque to rotate the pinion shaft is not exceeded. If excess preload is applied to the joint, the pinion shaft must be removed and a new collapsible spacer, pinion shaft tail bearing, pinion shaft tail bearing cup and pinion flange nut must be installed.

CAUTION:
The collapsible spacer will collapse under a load of 8-10 tons.





CAUTION:
Use a suitable pin to prevent special tool LR-150 from rotating while tightening the new pinion flange nut. (Figure 30)

9. Using special tool LR-150 tighten the new pinion flange nut until the end float on the pinion shaft is eliminated. (Figure 30)

CAUTION:
Ensure the specified torque to rotate the pinion shaft is not exceeded. If excess preload is applied to the joint the pinion shaft must be removed and a new collapsible spacer, pinion shaft tail bearing, pinion shaft tail bearing cup and pinion flange nut must be installed.

NOTE:
The special tool (205-067) should be rotated at 60 rpm (1 revolution per second) to produce a consistent reading.

NOTE:
The pinion shaft should be rotated through two full revolutions by hand before the torque measurement is performed.

NOTE:
It is not necessary to remove special tool LR-150 when checking the torque required to rotate the pinion shaft.





10. Using special tool 205-067, check the torque required to rotate the pinion shaft. The specified torque is 1.4 Nm +/- 0.2 Nm. (Figure 31).

CAUTION:
Ensure the specified torque to rotate the pinion shaft is not exceeded. If excess preload is applied to the joint the pinion shaft must be removed and a new collapsible spacer, pinion shaft tail bearing, pinion shaft tail bearing cup and pinion flange nut must be installed.

11. If the specified torque to rotate the pinion shaft is not reached, use special tool LR-150 to tighten the pinion flange nut in one degree increments. (Figure 30)

^ Check the rotational torque after each increment until the specified torque of 1.4 Nm +/-0.2 Nm is achieved.

12. Remove the special tool LR-150 from the pinion flange.

13. Remove the special tool (205-890) from the vice.





14. Remove the differential casing and pinion assembly from the special tool (Figure 32).





15. Install the crown wheel assembly (Figure 33).





16. Use a center punch to mark the differential with three dots in a triangular pattern in the position shown. (Figure 34)

CAUTION:
Ensure the mating faces are clean, before the sealant is applied.





17. Apply sealant to the differential upper casing mating faces. (Figure 35)

CAUTION:
Ensure the bearing cup and shim is retained in the differential casing.

18. Install the differential upper casing.

NOTE:
Tighten the bolts in the sequence shown.





19. Following the sequence shown, install the 12 differential casing bolts and tighten to 45 Nm (33 lbf-ft). (Figure 36)

20. Clean the RH driveshaft where the new clip is to be installed.

21. Install a new clip to the right-hand driveshaft.

22. Install a new O-ring to the differential housing and lubricate with petroleum jelly.

23. Using LRT-54-028, install a new left-hand driveshaft oil seal to the differential housing.