Maintenance and Service Manual 19 D Series : Planetary ee Drive 3 SPICER OFF-HIGHWAY PRODUCTS DIVISIONService Publications 1293 Glenway Drive Statesville, NC 28677 {© Cogyright DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION 1969 ‘Unpuoliened mataril + Aa rights resarvog Lewied Cision No part ofthe wore nay ba reproduoad in ary kam unWder ‘ry moans Without piroet writan permission of DANA SPICER OFF-HIGHWIAY PRODUCTS DIVISIONFOREWORD ‘This manual has been prepared to provide the customer and the maintenance personnel with Information and instructions en the maintsnance and repair of ‘the DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION product, Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. Tha slight outlay In personal attention and cost required to provide regular and proper lubelcation, Inspection at stated intervals, and such adjustments as. may be indicated will be reimbursed many times in low cost operation and trouble free service, In order ta become familiar with the various. parts of the praduet, Its principle of operation, troubleshooting, and adjustments, t Is urged that the machanic study the instructions in this manual carefully and use it as a reference whan performing maintenance and repair operations. Whenever rapair or replacment of component parts is required, onty DANA SPICER OFF-HIGHWAY PROQUCTS DIVISION-approved parts as listed in th applicable parts manual should be used, Lise of “wil-ft’ or non-appraved parts may endanger proper operation and performance of the equipment. DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION does not warrant ‘epalt oF replacement parts, nor falures resulting ftom thea use of parts which are_not supplied by or approved by DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts,NOTESTABLE OF CONTENTS: DESCRIPTION .. LUBRICATION ‘AXLE END DISASSEMBLY AND REASSEMBLY WITH LIQUID COOLED BRAKES. LIQUID COOLED BRAKE DISASSEMBLY AND REASSEMBLY AXLE END DISASSEMBLY AND REASSEMBLY WITH DAY DISC BRAKES AND WITHOUT WHEEL BRAKES DRY DISC BRAKE SERVICE INFORMATION. AXLE END WITHOUT WHEEL BRAKES SERVICE INFORMATION, DIFFERENTIAL AND CARRIER ASSEMBLY .. DISASSEMBLY AND REASSEMBLY PINION BRAKE HEAD ASSEMBLY AND ADJUSTMENT POSI-TORO ASSEMBLY AND DISASSEMBLY... PLANET CARRIER DISASSEMBLY AND REASSEMBLY .... 86 LUQUID COOLED BRAKE INSTRUCTIONS... ocecenee nee neen 88 FACE SEAL REBUILDING AND INSTALLATION INSTRUCTIONS. . SPIRAL BEVEL TOOTH CONTACT CHART (Left Hand)... SPIRAL BEVEL TOOTH CONTACT CHART (Right Hand)... RECOMMENDED WHEEL MOUNTING TORQUE TABLE OF TORQUE LIMITS. WHEEL BEARING ADJUSTMENT... AIR CHECKING WHEEL ENDS AND CENTER SECTION. ‘CLEANING AND INSPECTION. NOTE: Metric Dimensions Shown in Brackets [ ].NOTES -2-DESCRIPTION The axle assembly has a epial bevel type ring gear and pinion with further reduction provided by planetary gear set within the whee! hub. PRIMARY REDUCTION ‘The spiral bevel pinion and ring gear transmit power through the center differential pinions, side gear and to the axle shaft. The spiral bevel different assembly is mounted on tapered roller bearings, which are adjusted by positioning of the two threaded adjusting nuts mounted in the differential carrier and cap assembly. The tapered roller pinion bearir (bate adusted and malmalned by 6 harGones an precision ground spacer positioned batween inn and outer bearings. Spacer is selected at assembly. ‘SECONDARY REDUCTION in the wheel hub, a setf-centering sun gear is spline fitted to the axle shaft and drives three planetary pinion gears. These gears in turn mesh with and eact against a rigidly mounted internal ring gear, The planot gears rotate on needs roller bearings mounted, (on hardened and ground pins located in the planet carrier which in turn drives the whee! hub. Positive lubrication keeps all moving parts bathed in tubricant to reduce friction, heat, and wear. {L.CB) LIQUID COOLED BRAKES . ‘he liquid cooled brake is Ideal for use in Contaminated or temperature senstive environments and in machines where extra long maintenance intervals are required, Braking action of the liquid cooled brakes is achieved through the application of the hydraulic piston with the rotating friction ‘surlaces which react with stationary stator plates. The stator plates are retained by scalloped tangs at the ‘outside diameter, which in turn transfer the reaction orque to the rigid outside housing. ‘Tangs on the 0.0. of the friction discs prevent the «discs from dropping out of algnment when the wheel ub is for wheel bearing adjustments, This provides ease of service reassembly. Hub splines are long enough to engage all friction discs before bearings or seals are set. This. provides ease of assembly and assures the ability to ely adjust wheel bearings. ‘Whee! bearings can be serviced as in any normal bearing service procedure. RECOMMENDED LUBRICANTS FOR CLARK DRIVE AXLES Initia Fit Grade 8W140 qualified MIL-L-2105C gear lubricant as spaciled in Clark MS-8 engineering standard is proferrod {or initial fil for most ambient temperatures. (See chart on page 4.) For other ambient temperature ranges use proper viscosities of MIL-L-2105C. (Cther lubricants approved to MiL-L-2108C specifications are acceptable for initial fl or top of Service Fill Multipurpose gear lubricants approved to the MIL-L-2105G specifications. are recommended. MIL-L-2105C classifies multigrade gear lubricants on the basis of the viscosities al various temperatures, culli2don,page 4 ae the recommended munigrade viscosties for use at the Prevaling operating temperatures in ive Axles. MS-8 EXTREME GEAR LUBRICANT MS-8 specificalions cover a gear lubricant for use in heavy-duty axles. It is a highly refined base stock properly ‘compounded with selected exireme pressure additives. MS-@ meets MIL-L-2105C but is fortified with an additive package that provides added protection during the brealcin period and reduced wear and improved efficiency during subsequent operation APPROXIMATE LUBRICANT CAPACITIES Note: All quantities are shown in pints: 1 pint — 1 pound — 1 [liter] Below listed capacities are approximate. Fill to proper level as instructed in this manual. Aways fill wheel ends and axle cemters to the bottom of the oil level plug hole. ‘Axle Series Brake Type Each Wheel End ‘Total 19D ca 104.7] 93 [44,0] 19D Dry Dise 6 [3,0] 88 [46,4] 19D None 1316.0) 78 [36.5] NOTE: For brakes with extemal cooling see page 91.=, For props vcosiy be. ts Ere oc chat below. Tempera wea] Gear Lubricant Chart 10 mo ty # ‘ Multigrade Viscosities tl y ‘MIL-L2105C wo Ambient Temperature Ranges See (a) nate below. wily 40°F to IF (40°Cto-25°C) — T5WSee (b) ante below. o 40F to OF (40°C t0-18°C) ‘7580 sore og TT Sawa AF to +100°F (40°C to -38°C) mswo0 ® A0'F + Above (40°C + Above) 7EWH40 wt! w yewwa 18°F to 100°F (-28°C 10 38°C) soWw00 wm) “ISR + Above (26°C + Above) soW140 ailo 410°F + Above (12°C + Above} S5WH40 a 0 Notes: a a) The MIL-L-2105C Specification replaced the MIL-L-2105B ww 4]™ { Specification. 7M tym rete “ ) The MIL-L-2105C 75W Classification replaced the 40 F440 MIL-L-IM3244, Subarctic Specification. 0 ‘a f} rearvinen <7) cate Note: Specifications are subject to chanae. Liquid Cooled Brakes (LCB) A. The following oils are allowable to use on the actuator side of the 10,000 & 20,000 series liquid cooled brakes 1 Motor Oil API SE/CD. 2. MIL-L-461528/MIL-L-2104 C or D. 3. ATF C-3 or *DEXRON®, Not *DEXRON II (See Note Below). 4 Hycdrandie: Oils, 5 Water/Ol Invert Emlsion 6 Synthetic Gear Oils (Chemical Ester} B. Brake sump cooling oils (when external cooling is used), The following cooling oils are recommended in order oF preference, = Organic Esters 2 Hydraulic Oi 3 MIL-L-46152B/MIL-L-2104 G or D. 4- ATF. or "DEXRON®, Not DEXRON II* (See Note Below). 5 ~ Motor Oil API SE/CD. 6 Invert Emulsion and sll of the ols A above can be used inthe brake sump except water/oll avert emulsion must not be used with the LCB 10,000 series shipped fiom Clark before 1 June 1984 because af iacompatibility with the friction dises G. Ade assemblies with Liquid Cooled Brakes having a common brake and gear sump (ne brake external cooling used), se 1 Gear Lubricant mecting Clark specifications MS-B, 2 MIL-L-2105C, NOTE: DEXRON Il is not compatible with graphic frietion plate material unless ft meets the approved C-3 specifications. DESO emg et of Soe Mat Corpor,CHECKING OIL LEVEL IN DRIVE AXLES For off-highway operation, check lubricant level after each 250 hours of operation. Always maintain lubricant level to bottom of filer plug hole. Drain oil every 2,500 hours or one year, whichever comes frst. For highway operation, lubrication should be checked each $,000 miles [2,000 km]. Maintain lubricant level to bottom of filler plug hole. Drain ail every 25,000 miles [40,000 km] or one year, whichever comes first. To check oll level in axles with differential drive and planetary wheel ends, the axle should ba run first, then allowed to stand for a minimum of five minutes on level ground. This procedure will allow oil to drain back te its normal level, After the five minute interval, remove oil filer plug at axe canter andin the planetary wheel ands for oll level inspection. If ail level is not to the bottom of the filer hole, add necessary lubricant." LIQUID COOLED BRAKE - LUBRICATION ‘The self-contained liquid cooled brake system uses the same lube as the axle canter section and wheal ends. ‘There are no seals between the spindles and wheel hubs. Oil that lubricates the differential and planetary wheel ends also lubricates and cools the brake assembly. The oil level is the same height as the planet and axle center and the brake may be filed and oll eval checked at the planet carrier assembly or planet cartier cover. Brake oil changes would be accomplished al the same time the axle lube is changed. Contaminates resulting from braking will iot affect axle within normal oll change periods. CAUTION: On all axles with liquid cooled brakes, check brake drain plug for presence of axie lube for axes. without forced cooling, or cooling tluid for axles with forced cooling LIQUID COOLED BRAKE - DRAINING To drain the brake housing, remove the botiom drain plug from the brake housing. Remove the inlet plug below the bleadar screw. Allow enough time for housing te drain completely. CHECKING AND FILLING PLANETARY WHEEL ENDS ‘Always check lubricant level in planetary wheel ends, with wheel hub all lavel plug in a down position. Flamove oil level plug. If lubricant is below oll level hole, remove filer plug and fill to oil level hole." Reinstall pipe plugs. DRAINING THE AXLE CENTER AND WHEEL ENDS Draining is best accomplished immediately after the vehicle has opsrated a short time or completed a trip. The lubricant is then warm and will flow freely, allowing full drainage in minimum time. This is particularly desirable in cold weather. Remove plug at bottom of axle housing and allow sufficient time for lubricant ta drain. With planetary wheel ends, rotate wheel unt filer hole is dawn. Remove plug and allow sufficient time for draining. Be sure planet cover oil level hole is in proper position when refilling wheel ends. * NOTE: When filing the axle housing, planetary wheel ends, and brakes, allow anough ‘ime for lubricant to flow through the various components in the differential, planstary housing, and the brake assembly. After filling is completed, allow a faw minutes tor lubricant to attain its level and recheck each wheel end and the axle canter. Add lubricant if necessary.10 12 13 14 15 16 7 18 19 2a DRIVE AXLE ASSEMBLY WITH LIQUID COOLED BRAKES Description Quantity Internal Gear Hub Bearing Adjusting Nut... Bearing Adjusting Nut Lock... Bearing Adjusting Lock Capscrew Ade Shaft. Sun Gear Thrust Washer... Sun Gear. Planet Carrier Assembly... Planet Fillar Hole Plug .... Planet Carrier Attaching Screw... Planet Garrier Attaching Screw Washer ......36 Outer Hub Bearing Cone .. Outer Hub Bearing Cup Whee! Stud Whee! Hub .. Whee! Stud Nut, Inner Hub Bearing Cup... Inner Hub Bearing Cone ...... Hub Oil Seal... Hub Face Seal. Breather 22 2 24 5 26 or 28 28 30 a 6 36 a7 38 39, 40 " Description Elbow .. Name Plate Screw Name Plate Seal Ring Multi-Disc Brake Assembly... Brake Breather Spindle Attaching Nut Spindle Attaching Washer. Spindle Seal Housing Filler Hole Plug... Differential and Carrier Attaching Stud .......4 Differential and Carrier Assembly Differential and Carrier Attaching Nut Differential and Carrier Attaching Washer,,...14 Differential and Carrier Attaching Dowel........4 Differential and Carrier Attaching Stud ... Housing Drain Hole Plug Differential and Carrier Attaching StudAXLE ASSEMBLY INSTRUCTION ILLUSTRATION 19D SERIES (WITH LIQUID COOLED BRAKES) Astrum antacop run yan toa tor im mag ave 2d pooty Lostita #282 Thread Locking Comaound, A\ sop Loctite Pipe Sealant with tio, Hem No ‘boat AX sont Dow Coming FITY-28-7069 Sealant Bd eo ssa to banc chockad at 12 P81, (83 Pa) for ts seconds wh norop ia pressure ssn o EP ta Punose case Bs tony opt ot wat upon te spindle geal journal ameter prior to assembly. ‘was 1 BOLL PIN IN PLACE ‘TIONTEN TO 17S:90 LBFET tea Tee ate EEASSEMBLED TO AXLE saenta aoe Ay z nbn 57 sxe yousme Hae A hans ean nceston ety ‘iaeTEN TO es BF (LAT Nem) “ean FING #0R se eng ASSEMBLE PLANET CARRIER, Tuaina Teenie UNees museven ovner ARSMEATRESIG ARSE, Tread break cootaNr ouruer Al?500 UNP-2S THREAD SAE “O" FING aa fara ‘nie Sox lies Sake YD LET ‘THREAD BRAKE COOLANT eer UNIS WEAR INDICATOROVERHAUL OF AXLE ASSEMBLY WITH LIQUID COOLED BRAKES The instructions contained herein cover the disassembly and reassembly of the axle assembly in a sequence that would normally be folowed ater the unit hhas been overhauled. Mount aide on steel horses or ont \V-blocks, Allow axle housing meunting pads to rast an ‘crossbars of harses to provide necessary rigidity. NOTE: Drain axle wheel ends and center section thareughly before disassembly. See liquid cooled brake lubrication section for draining and filing brakes. (CAUTION: Cleanliness is of extreme importance in ‘he repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of diet and foreign matter entering the mechanism. ‘CAUTION: Before removing wheel hub and drum assembly install 4 “C" clamp an each end of axle heusing ta prevent axle assembly fram flipping aff repair stand, Figure 1 Position axle assembly on repair stand with flat area ‘of axle housing on cross bar of repair stand and the input flange of the differential up. Install "C* clamps as ‘explained in Caution above. Remove planet carrier to ‘whee! hub capscrews, Figure 2 Remove planet carrier assembly. Figure 3 Pull axle shaft out of differential side gear. NOTE: If only the differential is to be rapaired, repeat procedures in Figures 1, 2, and 3. Rlemove sun gear from axle shatt Figure 4 Remove sun gear thrust washerjure 6 Figure 11 ‘Support wheel hub with a strap and hoist. Remove Remove wheel hub and hub splines out of liquid ‘wheel hub adjusting mur, cooled brake (L.C.B} discs. —10-Remove face seal from brake housing end cap. Flemove wheel hub inner bearing, Figure 13 Figure 16 Remave face seal trom wheel hub. Remove triotion and reaction discs. The liquid cooled brake can be removed as an assembly and disassembled on the bench, but to remove as an assembly a very thin walled socket and @ universal socket adaptor must be used. The brake on this axle was partially disassembled on the axle and finished on the bench. Remove end cap bolts and washers. Fiemove piston pressure plate. Figure 17Figure 18 Remove brake and spindle stud nuts and washars, Figure 21 Pry spindle trom studs. Figure 19 Using one of the end cap bolts and a chain hoist, tap brake housing from spindle suds. — Figure 22 Reméve spindle to axie housing °O" ring. Figure 20 ‘SEE DIFFERENTIAL SECTION FOR DIFFERENTIAL Romave brake housing. ASSEMBLY REMOVAL FROM AXLE HOUSING. -i2-REASSEMBLY OF AXLE {Sse Cleaning and inspection Page) SEE DIFFERENTIAL SECTION FOR DIFFERENTIAL ASSEMBLY INSTALLATION IN AXLE HOUSING. Figure 23 Install a new *O" ring on spindle. Figure 24 Position spindle on axle hausing studs, = Figure 25 ‘Tap spindia on studs. -13- LIQUID COOLED BRAKE (L.C.B.) DISASSEMBLY AND REASSEMBLY DISASSEMBLY ‘See page 104 for Duo-Cone seal installation S. Remove bolt holding brake housing and spider together. Using a rubber hammer te protect the surface, tap brake spider tram housing. Tap dowel ping flush with spider machined surtace. Use caution as not to damage surface. Figure 28 Rlemove inner and outer back-up rings and sealing ring from brake spider,REASSEMBLY (See Cleaning and Inspection Page) Position naw "0" ring and sealing ring on housing. Remove inner and outer backup rings and sealing ring from brake piston, Install brake spider inner backup ring (piston inner sealing). Figure 31 _ —_ " Figure 34 Remove “G" ring and sealing ring tram housing. Install brake spider sealing ring (piston inner sealing). 14Figure 36 Align dewal holes in brake spider with dowel holes. in brake housing. Position spider on housing. Use caution 2s not to damage sealing rings. Figure 37 Tap dowel pins into brake housing ‘Tum housing and spidar aver, Start one bolt through housing and into brake spider. This will hold spider and housing together while assembling other brake ‘components. Install piston sealing ring (outer sealing)Figure 44 Install brake and spindle attaching washers and puts. Tighten 300 to 326 Ibft torque [410-40 Nem] Figure 42 With sealing ring and backup rings down, tap piston into brake housing. Use caution as not to damage sealing and backup rings on brake spider and piston. Figure: 45 Install piston pressure plate in housing, Figure 43 Position new “O" ring on brake spider. With brake bleeder screw at the top, align brake spider holes weith housing and spindle studs. Use caution as not to damage threads on studs. Install brake assembly. Figure 46 Apply Loctite #262 to stud threads. Install first steel reaction plate. -16-Figure 47 Install first friction plate. Alternate steel and friction plates until six (6) steel and six (6) fiction plates have been installed, Start with a steel plate and end with a frotion plate Figure 48, Install new housing ta end cap ail sealing ring. Remove top bolt from housing. Figure 49 Position end cap on brake housing, Figure 50 Install two boits in end cap to housing as shown and remove chain hoist, Install remaining and cap bolts. Figure 61 Tighten all brake end cap bolts in @ criss-cross ‘sequence. Torque bolts 175 to 190 Ibhft [240-260 N-m]. Figure 52 Pesition innar wheel hub bearing on spindle with large diameter of taper inwardFigure 53 ‘See page 93 for new face seal installation or rebuiid- Ing used seal, page 92. Position ona wheel hub face seal in brake end as explained on page 93. For external cooling brake see page 90 for hub seal installation. Position whee! hub face seal in hub as explained on page 93. Align wheel hub splines with brake discs. Insert hub splines into brake assembly. Use caution as not to damage hub seal. (Used with extemal cooling only.) Align hub splines with friction plates in brake ‘assembily—do not force this operation, When fully into position face seals in hub and brake will be together. Figure 56 Intall intemal gear and hub assembly into wheal hubs ‘and on spindle splines. Figure 57 Ingtall wheel bearing adjustment nut, NOTE: See Steps 1 and 2 in proper axle series wheal bearing adjustment on pages 98, 99, or 100. if er Figure 58 ‘See wheel bearing adjustment Step 3 for adjusting nut torque. -18-Figure 59 See wheel bearing adjustment Steps 4, 5, 6, 7, 8, for Wheel hub rolling torque {bearing protaad). Figure 60 Install adjusting nut lock plate per wheel bearing ‘adjustment procedure. Figure 63 Position sun gear thrust washer on axle shaft. Figure 61 Install lock plate screws per Step 9 in adjustment Figure 64 procedure, Install sun gear on axle shaft splines. ~19-Figure 65 ‘Coat wheel hub to planet carrier surface with Dow Coming ATV-C3-7069. Align sun gear teeth on axle shaft with teeth in planet canter gears. Install planet cartier in wheel hub, aligning notch in planet carrier housing with noteh in whee! hub. NOTE: Turn differential flange 10 facilitate assembly of axle shaft into differential side gear. Figure 66 ‘Apply Loctite #262 per guidelines and install planet caniier to whee! hub capscrews, Tighten to specified torque. See torque chart. Figure 67 Install planet carrier wheel end oil level and fil plug. SEE AIR TESTING THE AXLE CENTER AND WHEEL ENDS, PAGE 102. SEE LIQUID COOLED BRAKE TESTING PROCE- DURE, PAGE 80.NOTESoe Nm OR OD 10 " 2 13. 14 15 16 17 18 19 20 at g 28 ar 28 29 a0 a DRIVE AXLE ASSEMBLY WITH DRY DISC BRAKES Description Quantity item Description ‘Quantity Carter Washer 36 83 Spindle Seal... Carrier Capscrew... 288 34 Axle Housing... Planet Filter Plug... ok 35 Name Plate... Planet Carrier Assembly 2 36 Name Plate Screw. a Sun Gear. 2 37 Housing Filler Plug. Sun Gear Thrust Washer. 2 38 Cartier Stud... Bearing Adjusting Screw........ a8 39 Cartier Stud... Bearing Adjusting Nut Lock... 2 40 Differential and Carrier Assembly... -ccnet Boaring Adjusting Nut 2 41 Dawal Internal Gear Hub .. 2 42. Washer... ‘Axle Shatt ad 43 Stud Nut... Outer Hub Bearing Cone ... 2 44 Brake Disc Attaching Bolt Nut... (Outer Hub Bearing Cup 2 45. Brake Disc Attaching Bolt Washer... Wheet Stud 28 46 Braking Disc Whee! Hut ed 47 Brake Diss Attaching Bot Washar Wheel Stud Nut noe neeenn 38 48 Brake Disc Attaching Bott... Inner Hub Bearing Cup 2 49° Pinion Brake Mounting Bracket. Inner Hub Bearing Cone. 2 50 Pinion Brake Head Assembly Hub il Sa 2 51 Stabilizing Capscrew Nut Brake Disc Attaching Stud 32 52 Spring Washer Brake Disc. 2 53. Pinion Brake Mounting Brackat Capscrew. Dise Attaching Stud Taper Dowel. 8 54 Pinion Brake Mounting Bracket Caps ‘Washer... ttre ms Dise Attaching Stud Washer 2 55 Brake Head Stabilizing C ri Disc Attaching Stud Nut... a2 tana Capscrew Spring 86 Spring Washar Spindle Attaching Stud... 16 57 Brake Head Stabilizing Capscrew.. Spindle... oe 58 Differential Carrier Anaching Nut Brake Head Attaching Capscrew.. cB 59 Ditferential Carrier Attaching Washer. Brake Head Attaching Washer... nn B 60 Carrier Stud... Spindle Attaching Nut 2 . 61 Housing Drain Plug Spindle Attaching Washer... 32 2 Elbow Assembly. Dise Brake Head Adaptor son 63 Breather Assembly... wal Disc Brake Head Assembly .. = 2a-AXLE ASSEMBLY INSTRUCTION ILLUSTRATION 19D SERIES: Aa Tres srteon mumbo oy ands tm sea CE oe ar 2 boy Lacie 262 Tred Lacking Compound. 2 poniy Lnctin Pipa Sosiace with ttn, tor No. 0281. dro Bow Corning FTV.087069 Saslart. ‘Atte assembly to be-ait checked at 12 P.S.. (29 kPa} for 15 seconds with no dropin air pressure, 2\ Aeply coating of EP. Mult Purpose Groese ‘Grace #2 9 nside diameter of ol seals and to spindle geal journal diameter prior assembiy. Apply continuous coat of Loctite #515, Avg EAD Le ‘BREAK LOCKING COMPOUND {WITH DRY DISC BRAKES) HEAD THREADS OY PRION BRAKE READ ASSEMBLY ——[1088°N'm] often poem TAHT A TO, [sO7-a7a Nf oss arrOVERHAUL OF AXLE ASSEMBLY WITH DRY DISC BRAKES (instructions include Axles Without Wheel Brakes) The instructions contained herein cover the disassembly and reassembly of the axle assembly in a sequence that would normally be followed after the unit has been overhauled. Mount axle on steel! horses oF on Vblocks. Allow axle housing mounting pads to fest on crossbars of horses to provide necessary rigidity. NOTE: Drain axle wheel ends and center section thoroughly betore disassembly. CAUTION: Cieantiness is of extreme importance in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism. CAUTION: Before removing whee! hub and drum assembly install a “C" clamp on each end of axle housing to prevent axle assembly from flipping off repair stand. DISASSEMBLY ernie Figure 1 Position axle assembly on repair stand as shown. if only the diiferential is to be repaired, refer to Figures 12,13, 14, and 15 on both ends, IF PARKING BRAKE IS NOT USED, PROCEED TO FIGURE 10. Figure 2 Pinion parking brake is spring appliec’ and hydraulic released as a safoty feature. To remave the pinion ‘brake, pressure must be applied to brake until brake disc can be tumod. Figure 3 Loosen jam nut and tum adjusting soreweut of brake head. Figure 4 Remove cotter pins trom brake to bracket altaching bots.Figure 5 Remove brake head from bracket and disc. Figure 6 Remove brake pads. Remove brake dsc: to companion flange bolts, nuts, and washers. Figure 9 Remove parking brake bracket to pinion oil seal retainer bolts. Remove bracket. Figure 10 Install a °C* clamp to prevent axle from flipping off stand. Remove wheel brake head assembly to bracket bolls. Some units will have two (2) brake heads on each end. NOTE: For axies without whee! brakes proceed to Figure 12.Figure 11 Remove brake head assembly. (See page 25 tor brake head service.) “Figure 12 Remove planet carr to wheel hub bolts, Figure 13 Pry planet carrier away from wheel hub, Install a hook and hoist. Figure 14 Remove planet carrier assembly, Figure 15 Pull axle shaft out of differential side gear. Flemove sun gear and thrust washer.oe aes Figure 17 Remove whee! bearing adjusting nut lock plate screws. Figure 20 Remove adjusting nut. Figure 21 Remove lock plate. Remeve internal gear and wheel hub outer taper bearing. Figure 19 Attach a chain hoist to the wheel hub to prevent Figure 22 falling. Loosen whee! bearing adjusting nut. Remove wheal hub and brake disc assembly. —28-only if spindle or bracket is to be replaced. Some units will have bolts, nuts and washers. Figure 24 Remove brake bracket, NOTE: Some units will have two brackets on each end, Figure 25 Remove spindie. NOTE: For units without whee! brakes, see special section on face seal and retainer page 46. ‘SEE DIFFERENTIAL SECTION FOR DIFFERENTIAL ASSEMBLY REMOVAL FROM AXLE HOUSING. REASSEMBLY OF AXLE (See Cleaning and Inspection Page} SEE DIFFERENTIAL SECTION FOR DIFFERENTIAL ASSEMBLY INSTALLATION IN AXLE HOUSING. Figure 26 Position a new *" ring on spindle. Install spindle on spindle studs. Use caution as not to damage “0” fing. NOTE: On units not using an “O" ring, apply & continuous band of Loctite #518 sealant io spindle pilot diameter only. Axles without brakes install bons, washers and nuts as explained in Figure 28. Figure 27 Install wheel brake head bracket on studs. NOTE: Some units will have two brackets on each end. Figure 28 Apply Loctite #262 thread lecking compound per ‘guidelines. instal washers and stud nuts. Tighten to spectlied torque. See lorque chart. For axles without wheel brakes 866 special section on wheel hub face seal retainer installation page 45,WHEEL HUB AND BRAKE DISC DISASSEMBLY ‘AND REASSEMBLY For units without wheel brakes see special section page 44, DISASSEMBLY Remove brake disc stud nuts and taper dowels. Remove brake disc, Ramove wheo! hub oll seal and Inner taper bearing. Inner and outer taper bearing ‘cups need not be removed unless bearings are being replaced. REASSEMBLY (S09 Cleaning and Inspection Page} Press inner and outer taper bearing cups into position in whee! hub. Position inner bearing in bearing cup. ‘Apply a light flim of oil on both the ID and OD of the seal to facilitate installation into the hub and also onto the spindio, ‘Snap the seal onto the installation tool with the words *AIRSIDE" facing the adapter plate. NOTE: A print of the installation adapter is included in the text. Hold the tool straight and begin driving seal into the ub bore with a firm hit. Continue driving the seal until the sound of impact changes. This will indicate that ‘the seal is fully seated In the hub bore. Make sure the inner bearing rotates freely. THE WHEEL BRAKE DISC NEW IS .625 [15,9 mm] THICK. MINIMUM THICKNESS IN BRAKE PAD WEAR AREA NOT TO EXCEED LESS THAN 500 [12,7 mm]. IF LESS THAN 500 [12,7 mm] REPLACE DISC. Position brake disc on studs. install taper dowets on studs at taper dowel locations. Apply Loctite #262 per Quidelines. install stud nut washers and stud nuts ‘Tighten stud nuts at taper dowel locations first 300 to 330 Ibtlt [410-450 Nem]. Tighten remaining stud nuts to same torque then repeat complete cycle, Hub Seal Installation Tool Cn me waa rash Figure 23 Using a chain hoist, carefully position wheel hub and disc assembly on spindle. Use caution as not to damage wheel hub oil seal. NOTE: Align the wheel hub assembly with spindle and push into position. ‘Gare should be taken to avoid contacting the spindle ‘end during the assembly procass. Figure 30 ‘With whee! hub sill supported, position intemal gear ‘and outer whee! bearing in wheel hub.Figure 31 ‘See steps 1 and 2 in proper axle series. wheel bearing adjustment on pages 98, 99, or 100, Install wheel bearing Figure 34 adjusting nut. Remove wheel hub chain hoist support. Install adjusting nut lock plate. See Stop 9. Figure 32 ‘Soe Step 9 in wheel bearing adusimem, See Step 9 in wheel bearing adjustment. Figure 35 Figure 36 insert axle shaft in spindle and axle housing. -n- ; Figure 33 ‘See Steps 4, 5, 6, 7, 8 in wheel bearing adjustment,Figure 37 Position sun gear thrust washer and sun gear on axle shaft splines, Coat whee! hub to planet carrier surface with Dow Goming RTV-O3-7069. Align sun gear teeth on axle shaft with teeth in planet carrier gears, install planet carrier in wheel hub. NOTE: Tum differential flange to facilitate assembly of axle shatt into ditferential side gear, Figure 39 Apply Loctite #262 per guidelines and install planet carrier to wheel hub Gapscrews and washers. Tighten 10 specified torque. See torque chart. Figure 40 - Position wheel brake head on brake disc and bracket. NOTE: Some units will have two brake heads on each end, Apply Loctite #262 per guidelines and install brake bracket to brake head bolts and washers. Tighten to specified torque. See torque chart, SEE AIA TESTING THE AXLE GENTER AND WHEEL ENDS, PAGE 102,INLETS, 14-20 THREADS | VIEW XX. ASSEMBLE PLANET CARRIER: RECESS IN LINE WITH RECESS ON HUB TIGHTEN TO 90-35 LBF-FT [ao7-474 Nem END VIEW OF AXLEDRY DISC BRAKE ASSEMBLY Description Housing Backup Ring ...0. 10° Cylinder Head “O* Ring... Cylinder Head 11 Bloeder Screw...DRY DISC BRAKE HEAD SERVICE INFORMATION (Service Information Provided By Rockwell International) (GENERAL INFORMATION - FIGURE 1 ‘The calipers are used as service brakes for hydraulic: brake systems. Al calipers mount to a fixed position ‘on fixed-position discs. The caliper has four pistons with two pistons on each side of the disc. The linings are made from non-asbestos material ‘One or two calipers can be used on a disc. if one caliper is used, it is mounted at the 12 o'clock position. If two calipers are used, they are mounted at the 9 o'clock and the o'clock positions. FLUID For the tluid specifications, see the recommendations of the vehicle or equipment manufacturer. CAUTION Use only the specitied hydraulic tluid. Do not use different brake tluids. The wrong fluid will damage the rubber parts of the caliper. INSPECTION Inspect the caliper and the linings at the interval recommended by the equipment manufacturer or on aperiodic basis that depends on how the caliper is used. TWELVE O'CLOCK MOUNTING POSITION THREE O'CLOCK AND NINE O'CLOCK MOUNTING POSITION Figure 1 INSPECTION OF THE LININGS - FIGURE 2 Inspect the lining tor: A. Lining Wear — Replace the linings when the thickness of the lining is less than 1/8 inch [3 mm. B. Linings Wear Not Even — Replace the linings when the thickness of the linings is very different on each lining. Check the pistons for correct operation. Replace pistons that are locked in the bore, Check that the ise surlace is flat and parallel to the linings. C. Oil or Grease on Linings — Remove grease or oll with denatured alcohol or by reburnishing the linings. if grease or oll cannot ba remaved, replace the linings. D. Cracks on Linings — Replace linings that have cracks. NOTE: Gracks on the surface of the linings are normal when the caliper is used under high temperature conditions, CAUTION: Atways replace both linings. If only one lining is replaced, possible disc damage can occur.ZN LN Lig. ‘Grease oF all ‘09 fining (Cracked linings INSPECTION OF THE CALIPER HOUSING Inspect the following areas tor fluid leaks: A. Pistons — If the fluid leaks at the piston, disassemble the: caliper. Inspect the pistons, the bores, the °O" rings, and the backup rings. Service as Necessary, . Cylinder Head — If the fluid leaks at the cylinder head, fighten the cylinder head, the inlet fiting or the plug. if the leak continues, disassemble the caliper. Inspect the cylinder head threads, the: housing threads, and the “O" ring. Service as necessary. - Bleeder Screw — If fluid leaks at screw, tighten the bleeder screw. continues, replace the bleeder screw. bleeder f the leak . Inlet Fitting — If fluid leaks at the inlet fitting, tighten the fitting. Ifthe leak continues, the "O" ring must be replaced. FIGURE 3 Figure 3 INSPECTION OF THE DUST COVERS Inspect to make: sure that the dust covers are soft and can bend. Disassemble the caliper to replace dust covers that are hard or damaged, INSPECTION OF THE DISC - FIGURE 4 Inspect the disc. If the disc is wom beyond the wear limits, replace the disc. See the recommendations of the manutacturer for wear limits on the disc.disc wear; 0.06 inet (1.52 mm) TYPICAL SECTION THROUGH DISC SHOWING. RECOMMENDED MAXIMUM WEAR LIMITS, Minimum disc ‘thickness: 9.50 ine’ (12.70 mm) Maximum disc wear: 19.06 inen (1.62 mm) ‘Dise thickness: 0.625 inch (15.875 mm) Figure 4 REMOVAL AND INSTALLATION OF THE LININGS 1, Remove the bolts that fasten the end plates to one side of the caliper housing. Remove the end plates. 2. Loosen the bleeder screws to release the hydraulic pressure in the caliper. 3. Use a piece of wood against the linings as a pry bar 10 push the pistons completely into the heusing. Tighten the bleeder screws, FIGURE 6 4. Remove the tinings {rom the caliper housing. it ecessary, discard the linings. CAUTION: Always replace both linings. If only one lining is replaced, possible disc damage can occur. =37- 'S, Install the linings in the caliper housing. ‘6. Apply Loctite #271 of equivalent to the threads of the bolts that fasten the end plates to the housing. 7. Put the end plates on the housing. Install and tighten the bolts to 170 bf [230 Nom]. Make sure the linings move treely in the housing. 8. Remove the air from the brake system. See Bleeding the Brakes in this manual. 9. Apply and release the brakes three times to make sure the caliper operates correctly. Check for tuid leaks. Make sure the linings move {realy in the housing.REMOVAL OF THE CALIPER 41, Disconnect the brake line from the inlet fitting. Put ‘a plug in the brake line and the inlet fitting to prevent eontamination of the system, 2, Remove the bolts that fasten the end plates to the ‘ealiper housing, Remove the end plates. Remove the bbrake linings from the caliper housing. ‘3. Remove the fasteners that hold the caliper housing ‘on the mounting bracket. Remove the caliper housing from the mounting bracket. I shims are used between ‘the housing and the bracket, mark the postion of the ‘shims. INSTALLATION OF THE CALIPER, 1. if shims are used, put the shims in the position marked during removal. ‘2. Put the caliper housing on the mounting bracket. Install the fasteners that hold the caliper on the bracket, Tighten the fasteners to the torque specified bby the equipment manufacturer. 3. Install the brake linings in the caliper housing. ‘Apply Loctite #274 or equivalent to the threads of the bbolts that fasten the end plates to the housing. 4. Pul the end plates on the housing. Install and tightan the bolts to 170 tht-t [230 Nm} 5. Make sure the housing is installed correctly on the mounting bracket. The disc must be in the center between the linings. The linings must move freely in the housing. FIGURE 7 ‘6. Remove the plugs from the brake line and the inlet fitting. Connect the brake line to the inlet fiting. 7. Remove the air trom the brake system. See [Bleeding the Brakes in this manual. 8. Apply and retease the brakes threo times to make sure the caliper operates correctly. Check for tlukd leaks. Make sure the linings move freely in the saliper. Figure 7 DISASSEMBLY OF THE CALIPER 1. Remove the inlet fitting and the “O" ring from the cylinder head, Drain the hydraulic Muid trom the caliper, Discard the fluid, 2. Clean the outside of the housing with denatured alcohol. Dry the housing with compressed air or a clean cloth, 3. If installed, remove the bolts that hold the end plates on the housing. Remove the end plates and linings. 4, Remove the pistons from the side of the housing opposite the mounting plate according to the folowing procedure: ‘A. Use a C-clamp to hold a 1/2 inch [50 mir] bblock of wood against the two: pistons on tthe mounting sida of the housing. Make ‘sure the C-clamp is not in the area in front ‘of the piston bore. FIGURE 8 WARNING: Do net put your hand in front of the jstons when you force out the pistons. Personal injury may occur. Figure &B. Apply compressed ai to the inlet fiting to force the pistons out of the housing. it ene piston comes out before the other piston, put a piece of wood in front of the piston that comes out first. Apply comprossed air to force the other piston out of the housing. FIGURE 9 C. Remove the wood biock and the C-clamp. from the housing, 1D. Remove the pistons from the bores that {are oppostte trom the mounting plate. Figures 5, Remove the two blaeder screws fram the housing. 6. Put an-open-end wrench on the two flat areas ontop. of the cylinder head. Remove the cylinder heads trom the housing. Inspect the "O" ring on the cylinder head for cuts and damage. Remove and discard tha "O* ring. FIGURE 10 Figure 10 7. Remove the pistons from the mounting plate side ‘of the housing. Push on the ends of the pistons to ‘force them out of the disc side of the housing, FIGURE 11 Figure 11 &. Remove the dust covers from the housing. 9. Inspect the “O" rings and the backup rings In the housing for cuts and damage. Remove and discard the *O" rings and the backup rings. Inspect the ring grooves in the housing for scratches and rust Remove small scratches and rust with emery cloth, Replace the housing if there are large scratches or large amounts of rust. FIGURE 12 Backup Fling Figure 12 10. Inspect the pistons and the bores for scratches: and rust, Remove small scratches and rust with emery cloth, Replace the component i there are large scratches or large amounts of rust. +14, Measure the outer diameter of the piston, Replace the piston ifthe outer diameter is less than 2.996 inch [76,073 mm}. FIGURE 13Replace Piston it ‘Outer Diameter is Less than 2.995 Inch (76.073 men) Figure 13 12, Measure the inner diameter of the piston bore in ‘the caliper housing. Replace the housing if the inner ‘dareter of the bore is more than 3.008 Inch [76,276 mn. FIGURE 14 Figure 14 ASSEMBLY OF THE CALIPER CAUTION: Use only the specified components when ‘you assemble the caliper, Do not mix components jrom other calipers. If you install the wrong ‘componenis, the caliper will not operate comectly and may cause injury 10 the operator and damage lo the equipment 1, Use the hydraulic fluid that is used in the system and lubricate the following components: Pistons Backup Rings Bores Housing “O" rings Ring Grooves in Housing Cylinder Head"O" rings: Dust Covers 2. Install a new °O* ring and a new backup ring in the groove in the middle of the bore. The “O" ring is installed toward the outboard and of the bore. The backup ring is installed toward the lining side of the bore. ‘9, Install a new dust cover in the top groave af the bore. FIGURE 15 NOTE: The “O° rings, backup rings, dust covers, pistons, and bores must be lubricated with the hydraulic fluid used in the system before you can Install the pistons. Figure 15 4 Install the pistons in the housing. Push the pistons in from the lining side of the housing. Make sure the pistons are straight in the bores. Push each piston into the bore until the top of the piston is evan with the top of the dust cover. FIGURES 16 AND 17 —49-When Correctly lnstallod the End of the Piston fe Even with the Top af he Dust Cover Figure 17 5. Install a new "O" ring In the groove on the cylinder head. Make sure the “Oring is not cut by the threads ‘on the cylinder head 6. Install the cylinder heads in the caliper housing. Tighten the cylinder heads to 75 IbFft [100 N-m] as shown in Figure 18. 7. Install the bleeder screws in the housing, 8, Install the “O" ring and the inlet fitting in the cylinderhead. Figure 18 BLEEDING THE BRAKES You musi bleed the brakes fo remove air from the brake system when you remove and replace the caliper or the linings. if two calipers are used, bleed the caliper that is further from the master cylinder. Bleed the brakes a follows: FIGURES 19 ‘AND 20 1, Make sure that the fluid level in the master cylinder Is at the spectied level. It necessary, fil the master cylinder to the specified fluid level. See the recommendations of the equipment manufacturer for {he specified type of brake fluid and the specified fluid level, CAUTION: Use only the specified hydraulic fd. The wrong fluid will damage the rubber paris in the caliper. 2. Pul a lear tube on each bleeder screw. Submerge the other end of the tube in a clear container of the ‘Speeied brake fluid. 3. Loosen the bleeder screw that is further from the master cylinder. 4. Stowty apply low hydraulic pressure to the caliper. Do rot ralaase pressure. Continue to apply pressure tuniil bubbles: do not appear in the container of brake fluid. Tighten the bottom bleeder screw and then tighten the top blesder screw. Release the pressure 10 the caliper. Check the fluid level in the master cylinder. I necessary, fil 0 the specified level. See the recommendations of the equipment manufacturer.THREE O'CLOCK AND: NINE O'CLOCK Figure 20 : It an ais/hydraulic or mechanical actuator system is used, pushing the pedal to the down position does not remove all the air from the system, Tighten the bleeder screw belore returning the pedal to the up position so that air is net pulled back into the system, After the pedal is in the up postion, loosen the bleader scraw and push the pedal down until air is removed from the system. Tighten the bleeder screw betore releasing the pedal. 5, Loosen the bleeder screw that is closest to the master cylinder. 6. Slowly apply low hydraulic pressure to the caliper. (Do not release pressure. Continue to apply pressure until bubbles do not appear in the container of brake fluid, Tighten the top blesder screw. Release the Pressure to the caliper. 7. Check the fluid level in the master cylinder. Hf neo- essary, fill to he specified level. See the recommen- dations of the equipment manufacturer. ‘8. Apply and release tha brakes three times to make sure the caliper operates correctly. Check for fluid leaks. Make sure the linings move freely in the caliper.10 " 12. 13, 4 15 16 v7 18 19 2 22 23 24 25 26 DRIVE AXLE ASSEMBLY WITHOUT WHEEL BRAKES Description. Quantity tem Desoription ‘Quantity Internal Gear Hub 27 Axle Shatt. Internal Gear... 28 Thrust Bution Bearing Adjusting Nut . 29° Wheel Nut. Boating Adjusting Nut Lock... 80 WHEEPHUD nnn cnr cnr 2 Bearing Adjusting Nut Capscrew. 31 Wheel Mounting Stud... enn Planet Cartier “O" Ring... 82 Breather AGSPIOT nen 1 Planet Caner Assembly... 2 B30 Breather nnn aol Sun Gear Thrust Washer... 2 34 Housing FIlEF PRIQ... nee enenne nnn Sun Gear. 2 35 Name Plate... col Sun Gear Snap Ring.. 2 36 Name Plate SCO ent nnntnn 2 Planet Cover “O" Ring, enncnnnnne 37 HOUSING... enn Planet Cover Thrust Button...... 38 Spindle End......... Planet Cover Assembly... wk 39 Seal Retainer... Gil Level Plug, Not Used On All Models .....2 40 Hub Oil Seal (Face Seal) . Planet Cover Capscrew 218 41 Spindie attaching Bo! Planet Cover Capsorew Washer... o.0.18 42° Spindle Attaching Washer... Planet Leve! PIUQ. en eneenrnneene 43° Spindle Attaching Nut Planet Camior Capscrew. 44 Housing Drain Plug. Planet Carrier Capscrew WaShar ..u0u40 45 Ditferential and Carrier Mounting Stud. intemal Gear Retaining Plate... 12 46 Ditterential and Carrier Stud Dowel. Internal Gear Retaining Bot... 24 47 Ditferential and Carrier Stud Washer Inner Hub Bearing CONE 2... uennrnnra 48 Differential and Carrier Stud Nut... nr 49 Differential and Carfier Assembly Hub Filler Hole Plug. 2 50 Dillerential and Caner Stud Outer Hub Bearing CUP oo oornnennnnnen 51 Differential and Carrier Stud... Outer Hub Baring Gone ..‘OVERHAUL OF AXLE ASSEMBLY (Less Wheel Brakes) NOTE: Procedure for disassembly and reassembly of axles without brakes are the same as axles with dry disc brakes except where noted. HW face seal retainer was replaced or removed trom the spindle, apply @ continuous coat of Loctite sealer #515 to the seal retainer area on the spindle. I is recommended the seal retainer be heated to 375°F [190,6C] and pressed against shoulder on spindle. Press inner and outer bearing cups into position in wheel hub. Position inner bearing in bearing cup. Install face seal in seal retainer and in wheel hub per instruction on face seal installation on page $3. Reter to Figure 29 on page 30 for axle reassembly. Wheel Hub and Stud Assembly Internal Gear and Hub Assembly Install Face Seal Wheel Bearing Adjusting. Per Instruction Drawing Nut Lock Plate Lock Plate Cap Screw Wheel Bearing Adjusting Nut- See Wheel Beari Adjustment Pr lure Apply Continuous Coat Of Press Seal Retainer Loctite #515 Sealant To Against Shoulder Diameter Of Spindle‘The Clark-Hurth POSI-TORO limited slip differential is designed to pravent the savere loss of traction which occurs when one wheel encounters adverse tractive conditions such as slippery, wet, muddy conditions and the uneven terrain often encountered in off-road vehicle operations, This terrain can cause the vehicle to become DIFFERENTIAL ASSEMBLY SERVICE (LIMITED SLIP, NoSPIN AND STANDARD) DESCRIPTION OF THE LIMITED SLIP HIGH TORQUE BIAS DIFFERENTIAL immobile because of the spinning cf ona wheel. The Clark-Hurth POSI-TORQ differential uses clutch plates (which may optionally be spring loaded) to inhibit spinning and send torque to the high-taction wheel. With the spring loaded POSI-TORQ, the wheel with the bast traction can have up to five (5) times the torque of the wheal with poor traction (5:1 bias ratio) at low torque levels. Tho use of clutches in the differential provides high torque bias while maintaining a smooth differential action, This eliminates the drive line shock Inherent in locking type differentials, FEATURES: Increases traction in adverse driving conditions over a stands Rescuices tire wor. Eliminates shock loadings caused by locking differentials, Improves steering over a locking differential Directs torque away irom a slipping wheel to the wheal with the most traction, Provides up to five (5) times the torque to the tractive wheel as to the slipping ‘wheel at low torque levels, Uses a quiet four (4) pinion gear differential with each pinion backed by a. replaceable thrust washer to reduce maintenance costs. Available in two. (2) versions — without springs and with springs depending on application requirements. Available on many Clark-Hurth axle models, -47-LIMITED SLIP DIFFERENTIAL General Description The limited slip differential is similar in construction to the torque proportioning or conventional differential. The difference is that the limited sip differential contains a set of discs, like those used in the Clark-Humth transmission, which are mounted between the differential side gears and differential case. These discs limit the amount of “differential” according to the amount of torque transmitted through the differential assembly." The purpose of the limited stip differential is to give better traction characteristics than a torqua proportioning or conventional ditterenttal ‘and to give better “differential action” when tuning than the “nospin’ differential. The result is a compromise which provides good traction and less tire wear. * Differential action is that function of a differential which allows the outside wheel to rotate faster than tha inside ‘wheel when turning a machine Operation \n the limited slip differential there is a set of intemally splined discs and a set of externally splined discs behind each side gear. The internal discs are splined to the side gear and must rotate when the side gear rotates. The ‘external discs are splined to the differential case and must rotate when the differential case rotates. The amount of torque transmitted through the differential assembly determines the force the side gears exert against the discs When a small amount of torque is transmitted through the axe assembly, the side gears have Irtie side thrust. When a high amount of torque is transmitted through the differential assembly, the side gears have a high side thrust and the discs are compressed together. When a machine is traveling straight, the side gears and the differential case are rotating at the same speed and there is:no slipping action between the discs. When a machine is turning, the side gears must rotate ata different speed than the differential case. The discs must slip. The amount the discs slip is controlled by the pressure exerted by the side goar and the degree the machine is tured, If the torque transmitted through the axie is low, the disos are free to slip easily and “differential action” takes place easily. When the torque transmitied through the axle i high, the discs are compressed together by the force of the side gears and the “differential action” will nat take: place as. sasily, ‘As the discs wear through normal use, the side gears move farther outward. The limited slip differential is. selt- adjusting or self-compansating tor wear — the torque proportioning axle is not,Lubrication and Service The limited siip ditferential uses the same type of lubricant recommended for torque proportioning or conventional axles and the service interval is the same. For proper lubrication of the discs the oil level in the axle housing had to be raised to the center line of the housing. Any axle that comes from the factory equipped with the limked sip differential wil have an oil level plug property located in the center line of the housing. Itis extremely important that the oil lave! be kept at the lavel plug, If the oil level becomes too low the discs will not receive sufficient lubrication and will wear rapidly, Disc Replacement In the Limited Slip Differential Disc replacement time is determined by the amount of material collected en the magnetic drain plug. When the oil evel is checked, examine the drain plug for metal particles. A considerable increase in the amount of metal particles found on the magnitic drain plug indicates the necessity for replacing the discs. Disassembly and Assembly of the Differential Unit The limited slip differential unit is disassembled and assembled ike the conventional or torque proportioning differential unit, The only difference being the removal and installation of the discs. Note the position of the internally and externally splined discs when disassembling and replace the discs in the same position. =a9-‘Aasurea *masiwum traction” et all times, * Aulomatiealy permite wheal speed cittrentiation when ‘ohio tae © opetaian On uneven surfaces. ‘OPERATION Inman a ybicie equipped with a NoSPIN cifferntial is operated Ih leeward 0 Foverse ovat a smoath surface, tha NoSPIN re ‘malar locked. Bath wheats inva tur at the same speed. ane ‘wheel loves traction or laaves the ground, the appeal whos', ‘which silt has tactan, continues to are the vahscie Wnt TAC. Hoa is regained by Both whodis. Thark-can be na one whes! ‘pinout when using NoSPIN differentials. (Fx. 1) this weal wil me Fit \Whan the vahicle tens a corner, of wher: one wheel passes ‘ver an obstruction, the outside wheel, of the wheal paang rer the oosinacton. ust travel a greater stance ard erstore taser than the other whesi, When thin oscure, the NeSPIN differential automatically allows for the necessary ih toronce in wheel speed. (Pg 2) ‘A coenpeshecalve NoSPIN differs operation ‘and maintenance manual in avaliable st 9 ‘ominal charge. Contact service publications {or intormation a8 to how to order. Lubrication ‘The NOGPIN gittereatial is designed to operate in thase lubricants recommended by the vapicielanie Manufacturer. NO ‘Soaciallaioant is needed Fat carlain old weather apple fiona, use the lihest ol the axle manufacturer wal allow. Routine inapection Follow tha recommended lubrication, preventative maintenance ‘and inepection Grocedwies of the volclolaie manutactuer a8 Ball of NOSPIM aifterntia! provantative malnlenance. Maistecance, inspection ard lubrication requitemonts of [NOSPIN ciferentint equipped varicos are the same as vehicles with conventional aiterental. antec laratons shows ba made 1 he NoSPIN The performance ofa wehicie equipped with a NoSPIN difteren- {iat wl afer tram that ota vebsrle equipped witha conven Uienal dlleeeatial Fos exaenpie whan turing 2 corner, the sound of gear disen. ‘gagemant and reanpagemant may be audible, and fhe transter of driving tocgue from oth meee To one wheal may be noticeable whan going thom drive taccoleation| to coast (decelera- on} i's turn a metalic sound may be Deard ae torque ‘tow ig ravereed onsiga wheel engaged curing acceiers ‘ion: aut8ise whee! eagaged during deceleration). “Thana charactevitiesara normal Beeuxe Of Backlash eesigned tle the HOSPIN clfecentia \yiman negotiating a turn under conditions of poor traction, the inaide wtol may receive exceasive torque which mil cause ‘o-brauk traction This wil causa the tnaide wheel 1 sp the turn is completed or wall the Inside wheel catches up wi the ovitige mest A courion Oporaae ‘ors the engi ot and ase all ig wheels of 2 NoSPN ileal equi i ane when anging ters prver!Cwe tice ram men Aes, ewe wi NoSFIN eesti Geto! power oath wes —even when yee eG gra ‘eat opr iii 2am whens ta NASP oars equipped ae tae oct cog Pw Ve ly Se whe hh couse Sas Sing Be vite te mad ean smo sae. op net cee the wees aed ayn analy, hep tha dame lhe es wal. Fare 1 td ‘ree mapsres can cee 9-otisence navi wee spent whch can ‘aus Ee NOSPIN karl gate poe nly one te AE ‘eb cause Surg poner (erate nom ger men ceasing down nea urn. raking Capatiy ‘dca ws SREP GP ME EN OLS Be we casting Gown scant NeSPA gtaentts nave comeressos sponge. Uve a etairg ol e sme (Re eSTariag MEGS wb separa PG NB CEB ES. esPa aceprinssiatena cic,NOTES =51-10 12 13 14 15 16 7 18 19 20 21 22 23 DIFFERENTIAL AND CARRIER ASSEMBLY LIMITED SLIP Description Quantity tem Differential Adjusting Nut Lock... 28 Nut Lock Capscrew Lockwasher. 27 ‘Acjusting Nut Lock Capsorew....... 28 Differential Adjusting Nut 29 Ditiorential Bearing Cup... 30 Ditferential Bearing CONG een snenn a Cartier Cap Lochwasher..seecennenennnll 32 Cartier Cap Capscrew ..... 3 Ditterential Case Bolt... aa Differential Case Bolt Washer. neni 35 Differential Plain Half Case. 38 ‘Outer Clutch Dis. a7 Inner Clutch Disc... a 38 ‘Center and Outer Spacer 39 Pinion Gear Thrust Washer 40 Differential Pinion G8AC. cen 4 a Noe det ROUGE ener sve B82 4a Inner Spacer... 43 Pinion Gear Spider... 1 4a Differential Side Gear. 45 Ring Gear. 46 Flange Hall Case 7 Ring Gear Bott Nut .. wt 48 Ring Gear Bott... eB 49 Differential Caso Bolt Lockwasher Description Differential Case Bolt Inner Pinion Bearing ing... Inner Pinion Bearing .. Pinion, Ditterantiat Carrier. Genter Pinion Bearing Cone... Genter Pinion Bearing Cup... cnnoneneennt Pinion Bearing Cone Spacer... Pinion Bearing Cage Shim... -ononi AR Pinion Bearing C890 Ann enneenncnm 1 Outer Pinion Bearing Cup... Qutar Pinion Bearing Cone.. Pinion Oil Seal Retainer... | Seal Retainer Lockwash ‘Oil Seal Retainer Capscrew.... Pinion Seal.. Pinion Seal Washer .. ‘V-Ring Seal... Pinion Dust Shield... Wear Sleeve . ‘Companion Flange. Pinion Shaft Nut Washer. Pinion Shaft Nut Pinion Shaft Nut Cotter... AR - As Required40 " 42 13 14 15 16 7 18 19 a1 23 24, 25 DIFFERENTIAL AND CARRIER ASSEMBLY STANDARD AND NoSPIN Deseription Quantity Hem Description ‘Quantity Differential Adjusting Nut Lock.. 26 Inner Pinion Bearing Agjusting Nut Lock Bilt Lockwasher.. 27 Pinion 1 ‘Adjusting Nut Lack Bott... 28 Differential Carer. 1 Ditterential Adjusting Nut 28 Center Pinion Bearing Cone veel Diferential Beating Cup... 30 Center Pinion Bearing Cup.. Differential Bearing Gone... 2 31 Pinion Bearing Spacer . Differential Garrier Capscrew Lockwasher.....4 32 Bearing Gage Shir Differential Carrier Capscrew... $3. Pinion Bearing Cage 34 Outer Pinion Bearing Cup... Ring Gear Bait Nut.. 42 mer inom eee OP 35 Outer Pinion Bearing Cone Differential Gase Flanged Half... 86 Pinion Oil Seat Dowel Pin... 37 Pinion Oil Seol Retainer Ring Geer. 98 Oil Seal Retainer Lockwasher...... ing GAr Bot nonecnnne 12 39 Oil Seal Retainer Gapscrow.... 8 Side Gear Thrust Washer 40 Seal Thrust Washer Pinion Thrust Washer... 41°" Ring Seal. Pinion Ge 42 Pinion Dust Shield Pinion Gear Spider nnn A 43° Wear Siesve.. Side Gear. 44 Companion Flange. Difforential Case Plain Half. wal 45 Pinion Shaft Nut Wasne Case Capscrew Washer .. 8 45 Pinion Shaft Nut Deron Cease CREO cnn B 47 Pinion Shaft Nut Cotter... Differential Case Capsorew ... 48 Thrust Screw. Case Capscrew Washer... Dowel Pin: Bearing Retainer Ring, AR - As Required1850 DIFFERENTIAL AND CARRIER ASSEMBLY EX appny ocste 1282 Thevad Locking Campoune ‘opty costing of EP. Musi Purpase Grease Grade #2 Derwoen pe 9 oF eoais LS sopiy bow Sorsing FTVOS TOES Seatart ‘rote stl seat ura of sa tang win Bs sop toi #615 Sana Mu Purpose Grease Bove provided on caer haa Sorat No,. Carer ato, 8 0.8. won Nose ‘Standard diferential Noggin diteresia fit be aru a Sinis ep afateck 18 areal bostngs, Seize apace to cba a ‘ollng pon bering Ieee oes 19.23 infn fae np wn non assembled Io carer. ie check fo bs masa ‘serra Ie fncrnaed aid F210 Incluce pinion-ll seat crop. ‘See page 76 for PosiTorq Diferantial Body Assembly 1850 Series Differential (Ring Gear Diameter) Assembly Instructions & Bolt Tightening Chart — lb-ft Torque [Nm] 1 — ig Sen bac Agumer 1D — 175 to 100 wt (298257 Nem) 010-018 10,26-0,38} E = 125 to 140 (on [170-190 Nem] B— 25 10 28 lbh [36.38 Nem} Standard and NoSpin F — 800 Ib Min. [1084 Non] B— 15 to 18 Fn [e024 Nm] G— 175 to 190 bt [208257 Nem] Limited Sip ‘Standard and NoSpin ¢— 320 10 960 Ib [448-488 Nim G— 125 1o 140 men [170-190 Nm] ‘Standard and NoSpin Limited Sip © — 475 to S25 bth [675-710 Nim] Limes Slip -56-‘OVERHAUL OF DIFFERENTIAL AND CARRIER ASSEMBLY NOTE: Betore the dittarantial assembly can be removed, both axle shafts must be pulled out of the differential side gears. Axle shaft removal is. explained In the Wheel and disassembly and reassembly section. DIFFERENTIAL REMOVAL FROM AXLE HOUSING Figure 1 ‘With the differential positioned as shown with the input flange up, remave stud nuts, taper dowels, and washers. Remove differential assembly from axle housing. DIFFERENTIAL DISASSEMBLY AND REASSEMBLY The instructions contained herein cover the disassembly and reassembly of the differential assembly in a sequence that would normally be followed after the unit has been removed from the axie housing and is to be completely overhauled, CAUTION; Cleanliness is of extreme importance in the repair and everhaul of this unit. Blefore attempting any repairs, the exterior of the unit must be thoroughly cleaned to pravent the possibility of dirt and foreign matter entering the mechanism. -s7- DISASSEMBLY Figure 2 Mount differential on differential overhaul stand, Figure 3: Check and recard ring gear backlash with a dial indicator. This information is necessary for reassembly unless a new gear set is installed. Figure 4 Mark carrier cap and carrier housing to insure correct atch in reassembly.Figure Remove adjusting nut lock capscraw and washer, = both sides. Figure 8 lemove adjusting nuts and taper bearing cups. Figure 6 Remove carrier cap capscrews and washers on both sides. ig Remove differential assembly from carer. Figure 10 Remove carrier caps. Remove cotter pin and companion flange nut. -58-Figure 11 Remove flange nut and washer. NOTE: Some units ‘will have a self-locking nut. Cotter pin and washer are nat used with sellocking nut Figure 12 Remove flange. Figure 13 Remove oil seal retainer bot. Figure 15 Install two bolts in puller holes and pull bearing cago from cartier assembly. This pulls outer pinion bearing cone from shaft. Tum éach bolt equally to prevent damage to carrier, shaft, or bearings. After bearing cage is pulled out a short distance, back off puller screws and insert 030" shim stock under puller screws before pulling Is continued, to reduce possible damage to shim pack under flange of bearing cage.Remove pinion and bearing cage assembly. Retain shim pack for possible reuse at reassembly. Figure 17 Press pinion shaft and center bearing from outer bearing and bearing cage. Figure 18 Press center bearing from pinion shaft. Figure 19 Remove inner pinion bearing retainer ring. Figure 20 Press inner bearing from pinion shaft Figure 24 Remove pinion bearing cups anly if they are to be replaced or if the bearing cage is damaged.DISASSEMBLY OF DIFFERENTIAL CASE HALVES NOTE: Three different differentials were used in the text to cover all variations, i.e. Standard, NoSpin, and Limited Slip. Disassembly and reassembly of all of he above variations are included in the following text. IF LIMITED SLIP DIFFERENTIAL IS USED, SEE LIMITED SLIP SECTION, FIGURE 27, PAGE 62. IF POSL-TORQ DIFFERENTIAL IS USED, SEE PAGE 76, i NaSpin differential is NOT used proceed with Figure 22, HT NoSpin is used, use the following fer removing ‘and proceed to Figure 25, 1. Mark the mating halves of the differential case with a center punch so they can be reassembied in the original position when repairs or inspection is completed. 2. Insert a retaining bolt and washer assembly {as shown), threading the nut fingar-tight against the washer, 3. Separate the case halves and lift out the NoSpin assembty. Figure 23 Remove ditterential bolts securing case halves together, Lift off plain case half. Use soft mallet if necessary to ald removal Figure 24 Femove spider, pinions, and thrust washers. Figure 22 Match-mark case halves te ingure correct reassembly. Figure 25 Remove nuts and bolts. Remove ring gear.Figure 26 If replacement ie requieed, remove ditferential bearing cones with a suitable puller. LIMITED SLIP DIFFERENTIAL DISASSEMBLY NOTE: Match mark case halves and spider to insure correct reassembly. Remove differential plain half case. Limited slip discs and side gear may remain in half case. Remove discs and side gear. Figure 29 Ht side gear and discs remained on differential piniens, remove from pinions. Remove differential pinions, washers, and spider as an assembly, NOTE: There are two rows of needle rollers under each pinion gear. Do not lose these rollers. Figure 31 Remove flange half case side gear and limited slip dises from case, Use a split puller if half case taper bearings are to be replaced. See Figure 26. Remove ‘ing gear nuts and bolts if ring gear is to be replaced, Seo Figure 25.DIFFERENTIAL REASSEMBLY NOTE: All parts must be lubricated with Clark-Hurth recommended axle lubricant when reassembling. No part should be reassembled dry. PINION SHAFT AND BEARING CAGE REASSEMBLY Figure 33 Install inner bearing to pinion shaft retainer ring, -6- Figure 34 Press center taper bearing on shaft with large diameter of taper toward pinion gear. NOTE: A pinion bearing spacer and shim kit is pravided far ropair of carrier assembligs. This kit consists of spacer and a quantity of shims. If pinion, pinion bearings, or housing was not changed, use riginal bearing spacer for reassembly. Install pinion beering spacer and one 010 [0,254 mm] shim. Install inner and outer taper bearing cups in pinion bearing cage.Figure 37 Positien pinion bearing cage assembly on pinion shaft. Position outer pinion bearing cone on pinion shalt and press into place. Figure 38 Keep pinion and cage assembly in press with approximately 500 pounds of press pressure exerted on driver. Wrap several turns of saft wire or cord around pinion cage and pull in horizontal line with spring scale. While pulling in straight line, (90 degrees from center line of shaft), read spring seala and measure rotating torque. Multiply reading on spring scala by one-hall diameter of bearing cage to obtain preload torque. Gortect preload torque is 13 to 23 ltt [1-3 Nem. if preload is not within these limits, remove shims to increase preload or add shims to decreasa preioad. NOTE: This is a preliminary check. Final bearing preload check must be mada with pinion shaft and bearing cage assembly in ditferential carrier housing. Install bearing cage and pinion shaft assembly in differential carrier assembly without bearing cage shims. Use four (4) oll pinion seal retainer bolts with ‘at washers to pull pinign shaft assembly fully inte ‘carrier assembly, Make sure oll passages are aligned. Install three (3) flat washers on each bolt to prevent ‘them fram betteming, Figure 40 ‘Temporarily install companion flange on end ef pinion shaft without installing pinion oll seal retainer. Install ‘companion flange retaining tool an companion flange and tarque flange nut 1a 800 Ibi-t [1084.7 Nem. Remove companion flang “inch-pound” torque wrench to check bearing preload. i bearing preload is not between 13 and 22 Ibfin [1-3 Nom] disassemble parts and add shims to decrease preload or ramave shims to incteasa preload. jaining tool and useREASSEMBLY OF DIFFERENTIAL IF POSI-TORQ IS USED, SEE FIGURE 16 PAGE 78. ih Figure 42 Check ring gear mounting surtace of flanged halt of differential case for burrs. Remove burrs with file. Clean thoroughly of any metal dust. Ss Figure 43 Press differential bearing cones on case halves. Figure 44 Install ring gear. Install bolts 80 intemal diameter of ring gear prevents turning of hex head, Install ring gear bolt nuts and torque to specified torque. See torque chad. if NoSpin is used, install in case half as an assembly and proceed to Figure 47. If limited slip ditforamial is used, procead to Figure: 48. Figure 45 Lubricate and install thrust washer and side gear in differential case and ring gear assembly. Engage holes In thrust washer on dowels pro] thrust washer bearing surface in dittere —— oe Figure 46 Place pinions and thrust washers on differential spider, lubricate, and set in position on installed side gear. NOTE: It is very important that tang on each pinion thrust washer engages groove in case halves as shown. “a Figure-47 ‘Align match marks and install remaining case hal! on other case half assembly, making sure of full gear engagement. Install bolts and tighten to specitied torque, See torque chart.LIMITED SLIP DIFFERENTIAL REASSEMBLY NOTE: All parts must be lubricated with Clark-Hurth recommended axle lubricant when reassembling. No part should be reassembled dry. Position inner neadia roller bearing spacer on Gifferential spider. See Figure 53A for cross-section reference. Using a rubber band to facilitate assembly, install one row of needle rolist bearings. Install center roller bearing spacer, Figure 51 Using another rubber band, install outer row of needle roller bearings. Figure 52 Position pinion gear on nasdlas as shown, Remove first rubber band. Slide pinion gear over second row ‘of needles, Remove second rubber band. Figure 53 Install outer roller bearing spacer and pinion thrust washer. A rubber band was Used on each end of the spider after pinion installation to keep pinion gear in place until assembly into flange half case.“2 ‘are three: (8) outer discs and two (2) Inner discs for each side gear. SIDE GEAR PLAIN 0.0) [7 INNER DISC Install one limited slip outer clutch disc (teeth on the ‘outer diameter). See Figure S6A for cross-section reference. SCALLOPED 0.0. OUTER DISC Figure 564 Figure 55 Install one limited slip inner clutch disc (teeth on the inner diameter). Align side gear splines with teeth in inner clutch discs. -o7-Figure 58 Remove rubber bands holding pinion gears inte position on differential spider, Place spider assembly on side- gear. Install ane outer disc and one inner dise on side goat. Alternate discs untl a quantity of three (3) outer discs and two (2) inner discs are installed. Start with an outer disc and end with an outer disc. Align outer clutch disc ‘teeth to facilitate assembly into plain half case. Figure 61 Align match mark on plain half case with mark on ‘flanged half case, Install plain half case over limited ‘slip clutch plates and side gear. Figure 62 Apply thread locking compound as explained in ‘guidelines and install ease bolts and washers. Tighton to specified torque. See torque chart. RING GEAR TO PINION MOUNTING DISTANCE PROCEDURE A pinion getting gauge must be used to achiave a precise mounting distance between the ring gear, differential carrier housing, and pinion ‘The gauge should be used if either carrier housing ‘and/or ring and pinion Is changed. The use of the gauge will determine the amount of shims to be used under the pinion bearing cage to achieve an exact mounting distance between the ring gear and pinion. By using the gauge and adding the proper thickness of shims, an optimum tooth contact wll be obtained. Setting the ring and pinion mounting distance without the gauge will require a tral and error procedure. A shim must be Installed under the pinion bearing cage and then the unit must be completely assembled par Service manual instructions.‘The procedure must be repeated until proper tooth sontact is obtained. The following procedure is used to achieve a proper ring gear to pinion mounting distance using a inion setting gauge. Locating position of the pinion as described will produce a proper tooth contact with the ring gear ‘when it and the differential assembly are assembled and adjusted to proper backlash setting, Pinion setting gauge can be purchased from Service Tools, 2043 4th Streat, N.W., Gwatonna, Minn. 85060. Kit No. WME 1004-2. ‘The function of the gauge is to measure the Figure 63 ‘distance from the center line of the differential bearing Use a file and emery cloth to remove alll burrs and bbores to the ground surtace on the gear end af the nicks from machined bearing surtaces of differential pinion gear. This measurement, when subtracted trom cartier housing. ‘the value etched on the ring gear will indicate the size ‘of the shim pack required to position the pinion gear in proper ralation to the ring gear. ‘On the outer diameter of the ring gear, a ring gear to pinion mounting distance value will be etched. Add 469 to It (.469 is half the thickness of the gauge bar.) Record this valua. This value may be different on ach ring and pinion set due to manufacturing variations. Insert a 4" base 5/32" diameter extension depth micrometer and 5°-6" extension inte the quide bare ot ‘the micrometer arbor. Slide clamps over base of micrometer. With the thumb screws reacting on base, secure micrometer is a Figure 64 ss Paint bearing surfaces of carrier housing with gear ‘tooth marking compound. IMPORTANT: The micrometer extension must pass ‘rely through the micrometer bar guide bore and the base of the micrometer must rest on the micrometer arbor when mounted. Figure: 65 Mount adaptor disos on micrometer arbor and sot in Position in carrier housing as shown in Figure 65. Exercise care to be sure that micrometer and ‘extension da not contact any part of the carrer in this ‘operation. Apply pressure by hand and rotate adaptor discs slightly to obtain @ contact with be: surfaces,Remove checking gauge assembly and check tor full bearing contact on bearing surfaces. Figure 67 Hf contact is full and proper, again position checking gauge assembly in carrier and check distance to ‘ground surface on pinion (Figure 67). DO NOT apply PRESSURE to arbor or micrometer. Turn micrometer ‘carefully and evenly until tip of extension contacts tha ‘ground surface of the pinion. In the assembly shown, the distance measures 5.159 inches, the reading on the: micrometer being .159 inch. Subtract this reading from the value etched on the ring gear and this equals the amount of shims to be added between the pinion bearing cage and the carrier housing. Example: 5.159— Value etched on ring gear and haf the thickness of the gauge bar, 5.129 — Initial micrometer reading. 1030 — Add this value in shims. Remove bolts holding pinion bearing cage in differential carrier and remove bearing cage and pinion assembly, Install required shim pack and reinstall cage and pinion assembly in carrier, Tighten cage screws 125 to 140 IbEft torque [170-190 Nem] temporarily, ‘After adding required amount of shims, again mount checking gauge assembly and take a check reading. ‘The reading should now be .159 (5.159 inches) plus.or minus .002 inch. In other words, the reading should be ‘equal to value etched on the ring gear within .002 inch, Figure 68 Remove bolts holding pinion cage in housing Remove pinion and cage assembly. Apply Loctite #515 fo shims and joining surtaces. Reinstall pinion and cage assembly being sure all oll passages are aligned. Apply a light coat of Loctite #516 to the outer diameter of the pinion shaft oil seal. Press. seal in retainer (retainer and parking brake mounting fiange not as shown) with lip of seal toward pinion bearings. Goat outer bearing cage surface with Loctite #515 and install oi seal retainer, Figure 69 Apply Loctite #262 thread lacking compound to threaded holes and install retainer botts and washers. Tighten bolts 125 to 140 Ib torque [170-190 Nem],COMPANION FLANGE ASSEMBLY 12 [30] ‘WEAR SLEEVE DUST SHIELD V-RING SEAL FLANGE SS Figure 70 Press dust shield on flange as shown. Position V-+ ‘ea seal on flange. Apply a continuous coat of Loctite #515 fo the inside diameter of the oil seal wear sieeve. Press wear sleeve on flange to dimension shown. Figure 71 Apply Dow Corning RTV-Q3-7069 Sealant to pinion spline locations shown on assembly instruction sheet, ‘page 56, Install flange, washer, and rut. Tighten nut {to 800 lott torque (min }{71085 Nem}. Tighten nut until cotter pin hole Is exposed. Install rat cotter pin, See note Figure 11, page 59, Figure 72 Position differential assembly into carrier. =n- Position differential bearing cup and adjusting nut on one side of differential and litt slightly with hoist. Pesitian bearing cup and adjusting nut on carrier, Repeat procedure and install apposite bearing cup and adjusting nut. Tur adjusting nuts by hand to be sure of proper thread alignment. Coat internal threads: of bearing cap bolt holes in housing with Loctite ‘Sealer #262, Figure 74 Position bearing caps an bearings and adjusting nuts, making sure maich marks made during disassembly are properly aligned. Install cap bolts and tighten lightly. Da not torque at this time. Figure 75 Tighten bearing adjusting nuts to adjust bearings to zero endplay,Figure 76 Use a dial indicator as shown. Move ring gear by loosening one adjusting nul and tightening opposite adjusting nut. Adjust position until gear backlash is to backlash specifications (see page 56 fer new gear sel) or adjust to backlash noted at disassembly for used gears. When proper backlash Is achieved, tighten opposite adjusting nut to set preload on taper bemings. Using only thumb and forelinger, move ring ‘When ring gear becomes difficult to move, prooad on bearing is set. el Figure 77 Tighten differential cap bots 475 to 525 Ibi-t torque [645-710 Nem]. Recheck ring and pinion backlash and ‘bearing preload as explained in Figure 76 to be sure backlash is within spectications. Install adjusting nut look, capscrews, tighten 15 to 18 Ibi torque [20-24 Nem]. INSTALLATION OF DIFFERENTIAL Figure 78 ‘Check differential mounting flange of axle housing to be sure itis free of dirt and burrs. Coat differential to axle housing surtace with Dow Goming RTV-Q3- 7069. Align differential assembly with axle housing studs. Lower into position. Use caution as not to damage studs. Apply Loctite #262 to threads of studs. Figure 79 Install taper dowels on studs. Install lockwashers and stud nuts. Tighten taper dowel stud nuts first. Tighten to specified torque. See torque chart. IF PINION PARKING BRAKE IS USED, INSTALL AS. FOLLOWS: Figure 80 Install the pinion brake mounting brackel on the oil seal retainer. Apply Loctite #262 per guidelines and install bots and washers. Tighten to specified torque. ‘See torque chart.Figure 81 Position brake disc on companion flange. NOTE: Parking brake disc mew is 500 thick (12, 7] Minimum thickness in brake pad wear area not to be lass than .450 (11, 4]. H less than .450 (17, 4], replace dise Figure 82 Apply Loctite #262 per guidelines and install brake dise attaching capscraws and washers. Each capscrew will have a washer under the head and between this brake disc and nut, Tighten capscrews 40 specified torque. See torque chart. Figure 83 Apply pressure with a porta-power to release brake position from the brake dise pads on each side of the brake dise. Install the parking brake assembly in position over the brake pads Figure 64 Install brake to bracket bolts. and nuts. Figure 85 Tighton nuts and align nut with otter pin hole. With pressure applied brake assembly must “float” on bracket bolts. Install cotter pins. PINION BRAKE ADJUSTMENT Figure 86 Remove brake cover and Ieasan adjuster screw lack nut.Figure 87 ‘With hydraulic pressure applied, tum adjuster sorew ‘clockwise until the brake pads make positive contact with the brake disc. Turn adjuster screw counter- clockwise until the desired clearance has been reached. Secure the adjuster screw by tightening the lock nut. Install brake cov Figure 88 Adjust stabilizing capscrew into brake head. PINION BRAKE HEAD ASSEMBLY Hem Description ‘Quantity item Description Quantity 1 Plate Lining... 2 3 2 Bleeder. 10 3 Protective Cap 1 11 Piston... — 4 Retaining Ring .. 12 “U' Section Seal Ring 5 a 6 4 7 15 8 16 -T4=Posi-Torq Limited Slip Differential Performance Ranges POSI-TORO performs in a range dependent upon the size and design variation of the differential, The inchision of springs creates pressure on the clutch plates that can increase the tractive effort of the high traction wheel to as ‘much as five (5) times aver the wheel with the poor traction. As operating conditions improve and the torque level in the axle increases, the effect of the springs diminishes and the bias ratio declines. In a POSI-TOR without springs the cluich friction is proportional to axle tarque, so bias ratio is constant over the axle torque range. A bias of between 2 - 2.75 can be achieved in a POSI-TORQ without springs. -75-1850 POSI-TORQ apply ‘Multi Purpose E.P. Lubricating Gear Oil Ts Both SPACER THICKNESS CHART ‘Sides Of Cluieh Plates And Back Face Of Side Gear. in un 0805 | 1.2680-1 2753 Apply Loctite #282 Thread Locking Compound. 2 | ees 0700 | 1.2754-1 2816 Hem Description Quantny (1.7e]_| (52.398-82 553) ora | 1.2817-1.2080 ‘erent Pion Ga seeeaa 1 2 Pinion Gear Thrust Washer 3 Gapscrew Washer. - SELECT A SPACER BY APPLYING 1000 LBF [459 TO THE SIDE GEAR TO FLATTEN THE CLUTt PLATES. MEASURE FROM THE FACE OF THE SIDE DIMENSION "A" AND CHART SHOWN ABOVE TO DETERMINE SPACER THICKNESS gTghten To. 126341 LARFT nis19t Sn To 128-341 LARFT 131 Nm] -76-DISASSEMBLY AND REASSEMBLY OF THE SPRING LOADED: LIMITED SLIP POS-TORQ DIFFERENTIAL BODY ASSEMBLY NOTE: Spring loaded differentials are optional. The differential shown inthis text is spring loaded, Disassembly and reassembly are identical except where springs are shown, Figure 1 Remove body bolts from plain half Figure 4 abt, Figure 2 Mark plain and flange half case to insure correct re- Figure 5 assembly. Figure 3 Figure 6 Remove piain half case. Remove thrust plata. -77-Figure 7 Figure 10 Remove spring pack spacer (not as shown). Fremove flange hal spring pack, Figure 11 Remove spring pack spacer (not as shown). Figure 9 Remove differential pinions, washers, and cross as an assembly. NOTE: Thera are two: rows of ni rollers under each pinion gear. Do not lose these Figure 12 rollers, Remove thrust plate.DIFFERENTIAL BODY REASSEMBLY POSFTORQ WITH SPRINGS (See cleaning and inspection page) Remove side gear, = Figure 16 ‘Check ring gear mounting surface of flanged hatf of Gitferential case for burrs, being certain surface is ‘smacth and clean, Install ring gear. Install bolts 50 intemal diameter of ring gear prevents turning of hex head. install ring gear bolt huts and tighten 175 10 190, Ibt-tt torque [298-257 N-m], NOTE: Coat all cich plates and side gear surfaces with Dow-Corring Molykote G-N Paste. Figure 14 Remove inner and outer clutch discs. Figure 17 Figure 15 Install one (1) inner clutch plate (teeth on the inner Remove ring gear bolts and nuts. Remove ring gear. Giameter). Akemate inner and outer clutch plates until H the plain or flange half case bearings are to be four (4) outer and three (3) inner plates are installed. You replaced, remave with a suitable bearing puller. start with an outer plate and end with an outer plate.NOTE: A check must be made to determine the in Figure 50. A 1000 Ibs. force [4448 N-m] must be applied to the side gear to flatten the clutch plates. A press can be used, or as shown in Figure 80, a Y2"-13 [12,7mm] bolt and "Vz" [12,7 mm] thick washer top and botlom are used. Install as shown and tighten: nut 90 to 50 ibf-ft torque (40,7-67,7 N-mi. This is equivalent to 1000 Ibs. [4448 Nem] force, A flat bar is used to support the depth micrometer. Measure the distance as shown ‘and subtract the thickness. of the support bar to get dimension "A." Hf dimension “A” is between 1.2690 and 1.2753 [92,239-32,399], use @ 0605 [1,537] thickness ‘spring pack spacer. If dimension "A is betwean 1.2754 Figure 19 and 1.2816 [32,995-32,553]. use a .0700 [1,778] install side gear, aligning outer splines with inner clutch thickness spring pack spacer. If dimension “AT Is plate splines. between 1.2817 and 1.2680 [32,555-32,715], use a 0795 [2.018] thickness spring pack spacer. ThisFigure 21 Install spring pack thrust plate. Install selected spring pack spacer (spacer not as shown). install spring pack with all bevels in the same direction and with the large diameter of the bevel ‘against the spring pack spacer, NOTE: Four (4) springs per pack, -81- DIFFERENTIAL PINIONS, NEEDLES, AND CROSS REASSEMBLY NOTE: All parts must be lubricated with Clark recommended axie lubricant when reassembling. No part should be reassembled dry. Figure 24 Position inner needle roBer bearing spacor on diferertial ‘spider. See Figure 30 for cross section reference. Figure 25 Using a rubber band to facilitate reassembly, install one row of needie roller bearings, Figure 26 Install center roller bearing spacer,Using another rubber band, install outer row of needle: eden outer roller bearings. seven pace oan Position pinion gear on needles as. shown. Remove first rubber band. Slide pinion gear over secand row of needles, remove second rubber band, Install outer rolier bearing spacer and pinion thrust washer. A rubber band was used on each end of the spider after pinion installation to keep pinion gear in place until assembly into flange hat case,Figure 31 Remove rubber bands holding pinion gears into Position on differential spider. Place spider assembly ‘on side gear. See note after Figure 16. Figure 32 Install one (1) outer clutch plate (teeth on the outer diameter) in the plain hall case. Figure 33 Install one (1) inner clutch plate (teeth on the inner diameter). Atemnate inner and outer clutch plates urtil four (4) outer and three (3) inner plates are installed. You start with an outer plate and end with an outer plate, Figure 34 Install side gear aligning outer splines with inner ‘clutch plate splines. Use the same procedure explained in the note following Figure 19 for the plain halt case clutch plate ‘and side gear measurement to select proper spring ack spacer.LLL LEP ELE (spacer not as shown), ] Figure 36 Install spring pack wan all bevels in the same direction ‘on the pinion cross. NOTE: Large diameter of bevel up.Install spring pack thrust plate. Align match mark on plain halt case with mark on ‘flanged half case. install plain hail case over chiich plates and side gear. Remove side gear from plain half case. Position side gear on thrust plate. Figure 42 Install case half bolts and tighten 126 to 141 Ibft torque [174-191 Nem]. Install one (1) outer disc and one inner disc on side gear, altemiate discs until a quantity of four (4) outer discs and three (3) inner discs are installed. Start with ‘an outer disc: and end with an euter dise. Align outer clutch disc teeth fo facilitate assembly into plain half case. Apply Loctite #262 to threaded holes in case ‘See page 68 for Differential to Cartier Ring Gear to halves. Pinion Mounting Distance Procedure and Reassembly,Figure 2 Remove keeper plate. Hem: Description Quantity Figure 3 ‘Tap planet shaft from planet carrier. 10 Planet Shaft "0" Ring DISASSEMBLY Figure 1 Figure 4 Remove planet shaft keeper plate capscrews. Remove planet gear and needle rollers,Figure 5 Planet shaft, gear, rollers, and thrust washers removed, Repeat procedures in Figures 1 thru 4 tor ‘complete cartier disassembly. REASSEMBLY (See Cleaning and inspection Page) Figure 8 Install a new planet shaft “O” ring seal an shaft. Install shaft in carrier, through thrust washer, gear and rollers, Inner thrust washer, and inner carrier bore. Figure Apply grease to the inside of the pinion gear ta hold needle rollers in place. Install a raw of rollers in the pinion gear (see parts list for proper quantity). Position roller bearing spacer on top af rollers. Apply ‘grease above spacer and install top row of rollers, Figure 7 Using grease to hold in place, position a pinion thrust washer top and bottom. NOTE: Be sure tangs on washers are in grooves in cartier housing. Install pinion gear and bearing assembly between thrust washers. Use caution as not to disturb needle rollers. Figure 9 Align slot in shaft for keeper plate and capscrews. Install keeper plate. Figure 10 Install keeper plate capscrew and tighten self-locking screws 75 to BS ibf-t torque [102-115 N-m].Item 10 " 2 13 4 15 16 7 MULTHDISC LIQUID COOLED BRAKE ASSEMBLY Description ‘Quantity Multi-Disc Brake Assembly [Quantity Indicated for one (1) Wheel End) .. 1 Loeknut® 2... eceeeeeeeeeeeeeeeeees 2 Gr a Wear Indicator Pin’ veeceee T Pin “0” Ring’... vee T Cooling and Drain Plugs. ..... 0. MOM RING eee teen etree rae 2 Brake Inlet Protector (Shipping Only) ...... 1 OMFG eect AT Bleeder SOmW Lo. eee eeeeeeeee T Brake SPIE cece cece T Piston Sealing Inner Ring Assembly ....... 1 Housing and Spider Sealing Ring ........ 1 Housing and Spider Sealing Ring 1 Brake Housing... 2... a Brake Cap Attaching Washor............ 12 Brake Cap Attaching Bolt.........000... 12 -89 trem Description Quantity: a ee} 19. Brake End Cap - cette D 20 Housing and Spider Sealing Fing ......... 1 21. Friction Plate and Lining Assembly .... 3.0r6 22 Resection Plate... core BOFB 28 Piston Pressure Pinte ..... 6... cseesee AF 24 Brake Piston ceceeeee ceed 25. Piston Sealing Outer Ring Assembly....... 1 a: 27 Spider and Housing Pin... 2 28 “O" Ring... 6. ee eet e eee 7 BB Plug eee A 90 Slack Adjuster Screw... eee 8 31 Slack Adjuster Seal... cece B 82 Slack Adjuster Jam Nut oo... 00.2.0. 8 33 Slack Adjuster Seal... wecteeeeee 34 Slack Adjuster Acorn Nut . cece BD “Not on all models.LIQUID COOLED BRAKE - LUBRICATION ‘The self contained quid cooled brake system uses the same lube as the axle center section and wheel ends. ‘There are no seals betwoon the spindles and whee! hubs. Oil that lubricates the differential and planetary wheel ‘ends also lubricates and cools the brake assembly. The oll level is the same haight as the pianet and axle center ‘and the brake may be tiled and oil level checked at the planet carrler assembly or planet carrier cover. Brake oil changes would be accomplished at the same time the axle lube Is changed, Contaminates resulting trom braking will not affect axle within normal oll change periods, NOTE: FOR FORGED GOOLING, CONTACT CLARK-HURTH AXLE ENGINEERING. LIQUID COOLED BRAKE TESTING PROCEDURE 1, Connect a porto-power unit to brake line infet. 2, Pump porte-power up to about 500 P:S.1. [3447.4 kPa] and blood brake. After all air is out of baka, pump poro-power up to 1000 PS. [68948 KPa an lock of. The gauge wil show about 2S. (688.5 kPa] drop. AL this point the gauge should hold. After three (3) to five (5) minutes unos gauge, Iet pressure biced off so the gauge shows zero, then pump porto-power up to about 100 P.S.l. (689.5 kPa}. Lock off porte-power. Gauge should hold at 100 P25.!, [689.5 kPa), Let stand for about five minutes. If pressure holds, the brake does not leak, I there is. drop in pressure on the gauge the brake is leaking and will require a complete disassembly to replace the piston inner and‘or outer sealing ring. 3. After making a satistactory test, relieve pressure on the porto-power and remove. Reinstall brake ling and bleed brakes in a normal manner, of APPLY CONTINUQUS COAT OF LOCTITE NO. 262 ol TO GUTSIDE DIAMETER OF ALL METALLIC CASE — OiL SEALS BEFORE INSTALLATION. press ONLY NV THIS AREAFACE SEAL BREAKIN PERIOD WHEN MACHINE IS IMMEDIATELY DRIVEN FROM PRODUCTION FLOOR OR AFTER FACE SEAL HAS: BEEN REBUILT OR REPLACED, IT IS IMPERATIVE THAT A 15 MINUTE BREAKIN PERIOD BE CONDUCTED: AT NOT MORE THAN 25 RPM WHEEL SPEED, WHICH IS 5 MPH MAX. AND IN 1ST GEAR OPERATION ‘ONLY. THIS IS TO ALLOW THE SEAL RUBBERS AND METAL RINGS TO PROPERLY SEAT. RECOMMENDED LIQUID COOLED BRAKE COOLING OILS IT IS RECOMMENDED THAT AXLES WITH EXTERNAL COOLED LIQUID COOLED BRAKES (LCB) USE “TRACTOR HYDRAULIC FLUIDS" MEETING ALLISON C4 DESIGNATION FOR COOLING OIL. THIS FLUID HAS E.P ADDITIVE FOR IMPROVED FACE SEAL LIFE AND FRICTION MODIFIERS FOA HIGH TORQUE AND QUIET BRAKE OPERATION, -s1-SEAL REBUILDING INSTRUCTIONS FOR SPLIT SEAL INSTALLATION 1. The rebuilding kitincludes two (2) rubber rings (98 Figure 1) and two (2) lint free wiping cloths. Both of the rubber rings must have barbs as shown in the drawing. -_ eld Figure 1 Figure 2 NOTE: In rebuilding the seal do not intermix metal sealing rings. Keep originel mated metal sealing rings as.asot(soe Figuee 2). 2, Before rebuilding the seal inspect the two metal sealing rings in the following manner to determine if it is acceptable for rebuilding, (a) The sealing band must be within the outer half of the: narrow highly polished band on the sealing face. ing face (cee Figures 3 and}. The st ‘Seating band not within outer half of sealing face, Seal acceptable for rebuilding Seal not acceptable for rebuilding. ling face (b) The sealing band must be uniform in width and must be concentric with the 1.0. end 0.0. of the (eee Figure 5). IH the metal sealing rings do not meet the proper specifications. de not rebuild theseal—usa a complately new Figure 7 Figure 6 respawn, Sealing band not LD, and 0.0. of Seal not acceptable for rebuilding. ned as follows: 3. The metal sealing rings must be cl ny foraign material from the back of the metal sealing rings with a scraper or wire brush (see Figure {0} Remove 6). fb) Clean the metal sealing rings with # clean degreasing solvent then wipe with the lint free wiping cloths fumniahaet in the rebuilding kit (ate Figure 6), sling rings. Be sure the rubber ringe are completely seated ageinst the 4, Assemble the mubber sings to the metal beck of sealing faces (eee Figure 7). Apply a thin film of light oil t@ ane of the sealing faces, being careful nat te wet othersurfaces with oll (see Figure 7). Cleanliness is’ critical when handling these seals. ‘Sos page 93 for face seal installation instructions, and page 104 for Ouo-Cone installation instructions. —92FACE SEAL INSTALLATION INSTRUCTIONS (PROTALOING UPS) 1+ SEAL WTERFROE METAL SEALING Ras PLASTIC RETAINER, UBER ae 1. Examine the seal carefully and note ite four basic parts. it has two rubber members and two lapped metal sealing rings, On naw face seals a claar plastic retainer band is optional and is used only to hold the seals togethsr. Discard plastic band. Note thet both rubber members have barbs at the 0.0. The berbs are there to hold the seal halvas concentrically in their bores while you are making the assembly: that Is thelr only function, Its possible a push a rubber member off of the neck of the metal sealing ring. Do not instal the seal while itis in ‘his condition—the rubber member will not go back on the neck of the metal sealing ring by itselY, Before installing ‘the-seal, you must push the rubber mamber back on the neck ofthe motal sealing ring, When installing thé seal you mst hold it 40 that you will not dislodge the rubber members from the metal sealing INSTALLATION Ute PRE-WUEE RUTH ARE wee / rant men eae me c HAN STEP 1 STEP 2 2 The seal is intended to be held in its operating position by two countarbores, ‘One (1) of these bores will be in the wheel hub (a rotating member) and the other bore will be stationary (in the liquid cooled brake housing.) ‘The function of this seal is to prevent dirt from entering the axle énd o¢ axle lube from leaking. 3. An important point ta note is thet thera must be no oll or dirt on the bores, rubber members, of any araa ef the ‘casting axcopt the lapped face as explainad below. Any oll or diet in these areas must be removed with a clean ‘degreasing solvent. (A new seal ix peckaged and shipped clean at oland dirt, and ned not be re-cleaned unless it has became contaminated.) 4, Seals for split seal assembly may be shipped with their lappad sealing faces (Interface) lightly pre-lubed far inetsilstion under clean erwiconmental conditions. ifthe seal has not been pre-lubed.or has become contaminated, ‘the lapped face must be wiped clean and # few drops af light oil applied as 8 pre-lube. 5. Seal installation. {a} Remove oil and din trom the seal bores using a clean degreasing solvent, er band. (b) Ifthe seal was shipped with a clear plastic retsinae Band, remove ret {e} install one-half of the seal all the way into one bors, being careful not to get ail or dirt on the O.D. of the rubber member or dislodge it from its metal sealing ring. (See drawing installation, Stop 1.) Repeat the other half of the ‘S03! assembly inte the other bore, Note that the barbs hold the seal halves concer in the boras, {d) Fallow pre-tube note in Step 4, fo) When the inst a1 Facet llstion ‘complet {wheel hub to brake}, rotate the whee! hub 3 complete revolutions tosest the -93-SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART BBSS8BS MOVE Peon newtane RING GEAR — THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH. TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER A LIGHT LOAD ‘TOE BEARING ON BOTH SIDES OF TOOTH — GEAR SET NOISY, TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV- ING GEAR AWAY FROM PINION, AG. 3 HEEL BEARING ON BOTH SIDES OF TOOTH —GEARSET NOISY AND: ‘COULD RESULT IN EARLY GEAR FAI TO MOVE BEARING TOWARD: ‘TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION. AG. 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT BY PULLING PINIGN AWAY FROM GEAR (INCREASE MOUNTING DIS: TANCE. FIG. 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING TANCE BACKLASH ‘ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL MERE PION AWAY FROM PRecetne TH GIRICTION —PREGH mY TH OECTION, VVI~V00 BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU- LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL,SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART ‘neve mntons Own a (Goan ne Ta omc rroree Mave Revon AWAY HOM ‘Oba I TH GAREETION \akoe 88 ‘ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL RING GEAR — THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH, FG. 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH ‘WHILE UNDER A LIGHT LOAD. Fig. 2 TOE BEARING ON BOTH SIDES OF TOOTH — GEAR SET NOISY. TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV. ING GEAR AWAY FROM PINION. HEEL BEARING ON BOTH SIDES OF TOOTH —GEARSET NOISY AND COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD: TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD: PINION, LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DiS- TANCE. HIGH BEARING ON GEAR AND LOW BEARING ON PINION, CORRECT BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS. TANCE. VNANA IGG BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU- LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL. =95-Thread Sire 5/8 (.625) 3/4 (750) 7/8 (.875) 1 (1.000) CLARK RECOMMENDED WHEEL MOUNTING TORQUE PROPER TIGHTENING PROCEDURE (Use Tightening Sequence Shown) Hat Nuts and Hardened Washer 175-190 Lbs. Ft. [240-260 N.m] 300 - 330 Lbs. Ft. [410-450 Nm] ATS - 525 bs. Ft, [645-710 Num] 725-800 Lbs. Ft. [985-1085 Num} Hlat Nuts with Rim Clamps 250 Max. Lbs. Ft. [340 Nm] 350 Max. Lbs. Ft, [475 Nim] Spherical Nuts (240-275 Lbs. Ft. [825-375 Num] 450-500 Lbs. Ft. [610-680 Nm] 600-700 Lbs. Ft. [815-950 Nm] 750-900 Lbs. Fr. [1015-1220 N.m] APPROVED BY AXLE ECINEERING: 7 MARCH 1900TORQUE FOR BOLTS, CAPSCREWS, STUDS AND NUTS Grade § Identification, 3 Redial Dashes 120° Apart on Head of Bott Grade 5 Fastener Size lubricated and Plated Wack 80-90 Lbs. In. [9-10N itis 180-200 Lbs. In, [21-23 Nl Berd 25-26 lbs, Fl. [34-38 Nf rere a 24S tbs. FL [54-41 Nl 1/2-13 Wao 65-70 tbs. FH. (08-95 Non} 9/16-1:; shes 90-100 Lbs. Fh. (125.135 Nm Bey 125-140 Lbs. Ft. [170-190 Nun] 3/4-1 sale 220-245 Lbs. Fi, [200-230 Nim] 7/8-9 7/8-14 330-360 Lbs. Ft. [450-490 Nom) 1-8 1-12 475-525 Lbs. Ft. [645.710 Nm} 1-1/8-7 ite 650-720 Ubs. Ft, (690-975 Nom] V1/4-7 wisn 900 - 1000 Lbs. Ft. [1220-1360 Nm} -97- Grade 8 Identification, 6 Radial ‘Dashes 60* Apart on Head of Bolt Grade 8 Lubricated and Plated 110+ 120 Lbs. In. [13-14 NmJ 215-240 Lbs. In, [24-27 Nm] 35-40 Lbs. Ft. [48 - 54 Nom] 60-65 Lbs. Ft. [e268 Nm] 90-100 Lbs. Fr [125-135 Nm) 125-140 Lbs. Fi, [170-190 Nm) 175-190 Lbs. Ft. [240-260 Num] 300-390 Lbs. Fl. [410-450 Nam] 475-525 Lbs. Ft. [845-710 Nm] 725-800 Lbs. Fi. [985-1085 Nm] 1050-1175 Lbs. Ft. (1425-1600 Ne) 1475 - 1625 Lbs. Ft. [2000-2200 Nn] APPROVED BY AXLE ENGINEERING REVISED: 24 MARCH. 1980,AXLE SERIES 1902641 DRIVE AXLE WHEEL BEARING ADJUSTMENT PROCEDURE (ingle Wheel Bearing Adjusting Nut and Lock Plate) 1, Before wheel bearing adjustment is made, itis imperative all tapered bearing cones and cups be preased to fully seated position. DO NOT depend on the wheel bearing adjusting nut to ‘shoulder’ tapered bearing cups: ‘and cones. NOTE: Ifthe wheel bearing adjusting nut has an undereut on the inner diameter, the underout must ‘90 toward the internal gear hub. On axies with LCB brakes, release pressure before continuing (any brake drag, will affect obtaining correct rolling torque value). 2 Coat inner face of nut, spindle threads, and spindle eplines with brush-applied lubricant (Anti Seize or Never-Seez). 3. Install spindle nut and tighten to 800 Ibf-ft (1085 Nim] torque. Shock internal gear hub with heavy bar while ‘rotating wheel hub two (2) to three (3) times. Recheck nut terque—if nut moves, retorque to 800 Ibf-ft [1085 Nei] and repeat shocking and tightening as many times as necessary until 800 Ibf-ft [1085 N-m] does not advance nut. Loosen nut Ya to Ye turn and shock the wheel hub until a slight bearing end play is achieved and the whael hub» can rotate freely. 4. Using a torque wrench adaptor bar or other appropriate measuring device, determine the rolling torque of the ‘wheel end with the bearings in a no-load end play condition. Due to part imbalance, there will be a variation in rolling torque as the wheel hub is rotated. Record maximum value of rolling torque throughout a revolution. This valve will be the “ne-load rolling torqua’” (LCE up to 200 ibt-f (271 N-m], othors 25 to 100 Ibt-ft [34-136 N-mp}. 5. For field service torque nut to 400 Ibt-ft [542 N-m]. Shock internal gear hub with heavy bar while rotating wheel hhub two-(2) to three (3) times while shocking the wheel. Re-check nut torque—if nut moves, re-torque to 400 IbFft [842 Nom] and repeat shocking and tightening as many times as necessary until 400 lof-ft [842 N-m] ‘does:not advance nut. Then advance nut until thres (3) holes in lock plate line up with tapped holes in internal gear hub, 6. Check rolling torque—must be in the specified range as-shown on adjustment chart aver no-load rolling torque. 7, Hover the maximum preload, reduce nut torque as required to-obtain the specified range but not less than 800 IbFt [408 N-m] on nut. 8, funder the minimum preload, increase nut torque until preload is in the specified rolling torque range with lock plate holes aligned, but not more than 800 Ibf [1220 N-m] after rotating the wheel hub five (5) or more times. install lock plate and screws, tighten screws 20 to 25 Ibf-ft [27-33 N-m]. See page 101, Greater than no-load roling torque. BEARING PRELOAD CHART Brake Type [_New Bearings Used Bearings (Bearings in use 300 Hours or More) LcB ier Nel 10 to. 25 Itt [14-33 Nem] No Brakes 20 to 40 Ibi-tt Disc or Drum [27-54 Nm] 5 to 15 Ibttt [7-20 N-m] "NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING COMPOUND ON THREADS. USE ONLY ONE TIME, THEN REPLACE OR THOROUGHLY CLEAN USED SCREWS AND APPLY EITHER LOCTITE 262 (H| STRENGTH) OR LOCTITE 242 (MEDIUM STRENGTH). INTERNAL GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING SCREWS.AXLE SERIES 1902748 - D-97770 DRIVE AXLE WHEEL BEARING ADJUSTMENT PROCEDURE {Single Wheel Bearing Adjusting Nut and Lock Plate) 1, Before wheel bearing adjustment is made, itis imperative all tapered bearing cones and cups be pressed to fully seated position. DO NOT depend on the wheel bearing adjusting nut to “shoulder” tapered bearing cups and cones. NOTE: Ifthe wheal bearing adjusting nut has an undercut on the inner diameter, the undercut must {90 foward the internal gear hub. On axles with LCB brakes, release pressure before continuing (any brake drag will affect obtaining correct rolling torque value). 2. Coat inner face of nut, spindle threads, and spindle splines with brush-applied lubricant (Anti-Selze or Never-Seez). 3, Install spindle nut and tighten to 1000 Ibf-ft [1356 N-m] torque. Shock internal gear hub with heavy bar while rotating wheel hub two (2) to three (3) times, Fechack nut torque—if nut moves, retorque to 1000 Ibf-ft [1356 Nim] and repeat shocking and tightening as many times as necessary until 1000 Ibf-ft [1356 N-m] does ot advance nut, Loosen nut ¥% to Ye tum and shock the wheel hub until a slight bearing end play is achieved ‘and the wheel hub can rotate freely. 4, Using a torque wrench adaptor bar or other appropriate measuring device, determine the rolling torque: of the wheel end with the bearings in a nodoad end play condition. Due to part imbalance, there will be variation in rolling torque as the wheel hub is rotated. Record maximurn value of rolling torque throughout a revolution. ‘This value will be the “no-load rolling torque” (LC up te 200 laff [271 N-mj, others 26 to 100 Ibfft (34-135 N-m)). 5. For fisld service torque nut to 400 Ibf-ft [542:N-m]. Shock internal gear hub with heavy bar while rotating wheel hub two (2) to three (3) times while shocking the wheel, le-check nut torque—if nut moves, retorque to 400 Ibi [542 Nem] and repeat shocking and tightening as many times as necessary until 400 Ib-ft [542 N-m] does not advance nut. Then advance nut until three (8) holes in lock plate line up with tapped holes in internal gear hub. 8. Check rolling toeque—must be in the specified range as shown on adjustment chart over no-load rolling torque. 7. Mover the maximum preload, reduce nut torque as required to obtain the specified range but not less than 800 tft [406 Nem] on nut. & funder the minimum preload, increase nut torque until preload is in the specified rolling torque range with Jock plate holes aligned, but not mare than 900 Ibf-ft [1220 N-m] after rotating the whee! hub five (8) or mare times. 8.* Install lock plate and screws, tighten screws 35 to 40 lbfft [47-54 Nem}. See page 101 Greater than no-load rolling torque. BEARING PRELOAD CHART Brake 7; New Bearit Used Bearings (Bearings in use 200 Hours er More) 30 to 60 lb-ft Lee 1é1-81 Nem] 1010 25 Itt [14-33 Nem] ole or Drom 50 15 Itt [7-20 Nm] "NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING GOMPOUND ON THREADS. USE ONLY ONE TIME, THEN REPLACE OR THOROUGHLY CLEAN USED SCREWS AND APPLY EITHER LOCTITE 282 (HI STRENGTH) OR LOCTITE 242 (MEDIUM STRENGTH). INTERNAL (GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING SCREWS.AXLE SERIES 1909747 + 1903960 + 1904049 + 1904954 DRIVE AXLE WHEEL BEARING ADJUSTMENT PROCEDURE (Single Wheel Bearing Adjusting Nut and Lock Plate) 1. Before wheel bearing adjustment is made, it is imperative all tapered bearing cones and cups be pressed to fully S8ated position. BO NOT depend on the wheel bearing adjusting nut to "shoulder" tapered bearing cups and cones. NOTE: If the whee! bearing adjusting nut has an underout on the inner diameter, the undercut must ‘90 toward the internal gear hub. On axles with LCB brakes, release pressure before continuing (any brake drag will affect obtaining correct rolling torque value). 2, Coat inner face of nut, spindle threads, and spindle splines with brush-applied lubricant (Anti-Seize or Never-Seez) 9, Install spindle nut and tighten to 1200 Ibf-f (1627 N-m] torque, Shock internal gear hub with heavy bar while rotating wheel hub two (2) to three (3) times, Recheck nut torque—if nut moves, retorque to 1200 lb-ft [1627 Nem] and repeat shocking and tightening as many times as necessary until 1200 Ibf-ft [1627 Nem] does ot advance nut. Loosen nut \4 to V2 tum and shock the wheel hub until a slight bearing end play is achieved and the wheel hub can rotate freely 4, Using a torque wrench adaptor bar or other appropriate measuring device, determine the roling torque of the wheel end with the bearings in a no-load end play condition. Due to part imbalance, there will be a variation in rolling torque 48 the wheel hub is rotated. Record maximum value of rolling torque throughout a revolution. ‘This value willbe the “no-load rolling tonque'" (LGB up to 200 Inf t [271 Nm}, others 25 to 100 Ib ft [34-125 N-m)). 5. For field service torque nut to 600 IbFft [814 Nm]. Shock intemal gear hub with heavy bar while rotating wheel hub two (2) to three (3) times while shocking the wheel. Rle-chack nut tarque—if nut moves, re-torque to 600 lott [814 N-m] and repeat shocking and tightening as many times as necessary until 600 Ibt-ft [814 N-m] does not advance nut. Then advance nut until three (3) holes in lock plate line up with tapped holes in internal ‘gear hub. 6. Check rolling torque—must be in the specified range as shown on adjustment chart over novoad rolling torque. 7. Mover the maximum preload, reduce nut torque as required to obtain the specified range but not less than 400 Itt [542 Nem] on nut. 8 under the minimum preload, increase nut torque until preload is in the specified rolling torque range with Jock plate holes aligned, but not more than 1400 Ibf-ft [1886 N-m] after rotating the wheel hub five(5).or more times. 8.* Install lock plate and screws, tighten screws 35 to 40 Ibtit [47-64 Nem]. See page 101. Greater than no-load rolling torque. BEARING PRELOAD CHART (Used Bearings (Bearings in use 300 Hours or More) ra 1010 26 bt [14-33 Nem] No Brakes 20 10 40 I piece ese Pom “NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING COMPOUND ON THREADS. USE ONLY ONE TIME, THEN REPLACE OR THOROUGHLY GLEAN USED SCREWS AND APPLY EITHER LOCTITE 262 (HI STRENGTH) OR LOCTITE 242 (MEDIUM STRENGTH). INTERNAL GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING SCREWS. =100=AIR CHECKING THE AXLE WHEEL ENDS AND CENTER SECTION It is recommended an air check be made on each wheel end after assembly. This chacking device is comprised of a minimum 20 P.S.1. [206 kPa] air gauge, an air shut-off valve, an air regulator valve, ipa 186, pipe nipple, reducing bushing and air line connector. The oil level plug is removed from the planet cover and the checking device is installed in its place. Ramove the breather in the axle center and install a pipe plug in the breather hole. The regulator is opened to 12 F.SJ. [@2 kPa] on the gauge. The air shut-off (installed between the regulator and gauge) is, then closed. A 12 PSII. [82 kPa] pressure must be - retained for 15 seconds. If there is a pressure drop in eas than 15. seconds there Is an air leak at the wheel hut oil seal. it an air leak is detected it wll require a wheel end disassembly to correct the leak. Make both \Wwhigel and air checks. and the following canter section, air checks before disassembiing any of the axle to correct an air leak. Alr check the axle canter section the same way as the wheel ends except the checking device is installed in the air breather hole in the axle center. It an air leak is detected, locate leak and correct. Atter air check is made, reinstall ait breather in axle center. -102-CLEANING AND INSPECTION CLEANING ‘Clean all parts thoreughly using solvent type cleaning fluid, Wis recommended that parts be Immersed in cleaning fluid and moved up and down slowly untl all od lubricant and foreign material is dissolved and parts are thoroughly cleaned. CAUTION Care should be exercised to avoid skin rashes, fire hazards and inhalatien of vapors when using selvent type cleaners. BEARINGS Fiemove bearings from cleaning tluid and sirike larger side of cone flat against a block of wood to dislodge solidified particlas af lubricant, Immerse again in cleaning tluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moistur free comprassad air. Bo caretul to direct air straam across bearing to avoid spinning. Do nat spin bearings when drying. Bearings may be rotated siowly by hand to facilitate drying process, HOUSINGS Clean interior and exterior of housings, bearing caps, ‘te, tharoughiy. Cast parts may be cleaned in hat solutian tanks with mild alkall soktlons, providing these parts do not have ground or polished surfaces, Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and 8 water. Parts cleanad in solution tanks must be thoroughly rinsad with claan water to remove all traces of alkali. Cast parts may also be cloaned with steam cleaner. CAUTION Care should be exercised to avoid skin rashes and Inhalation of vapors when using alial clesners, ‘Thoroughly dry all parts cleaned immediately by using moisture-tree compressed air ar sol lntless absorbant wiping rags froe of abrasive materials such as metal fiings, ‘cantaminatad oil or laping compound, INSPECTION: The importanoe of careful and thorough inspection of alt parts cannot be overstressed. Replacement of all parts showing indication of wear or stress willsSrinata costly and avoidable failures at a later date. BEARINGS. Carefully inspect all rollers, cages, and cups for wear, ‘chipping oF nicks to determing fitnass of beavings for further use. Do nat replace a bearing cone or cup individually without replacing the mating cup or cone at the same time, After inspection, dip baarings in clean light oll and wrap in ‘loan lintlass cloth or papar to protoctthom until installed. OIL SEALS, GASKETS, AND RETAINING RINGS Replacemant of spring loaded oll seals, gaskets, and ‘snap rings Is more economical when unit fs disassembled than to risk premature overhaul to replace these parts at a {uture tima. Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly When being installed. Cutting, seratching, or curling unde lip of seal seriously impairs is olfciency, At reassembly, Nubricate ips of ail soats with Lubripiate, (GEARS AND SHAFTS magnactisk process is available, use process to chack parts. Examine tooth and ground and polished surtaces.on ‘all gears and shafts caretully for wear, pitting, chipping, nicks, cracks, or scores. Hf gear teeth are cracked or show ‘spots where case hardening is worn through, replace with new gear. Small nicks may bs removed wih suitable hone. Inepect shatts to make certain they are not sprung, bent, o° ‘splines twisted, and that shafts are trus. Ditferential pinions: ‘and side gears must be replaced a3 sets. Ditlerential ring ‘gear and bevel pinion must also be replaced as a set If sither is damaged, HOUSING AND COVERS housing, covers, planat spider, and differential ‘eas@ to be cortain they are thoroughly cleaned and that mating surfaces, bearing bores, etc:. are frew {rem nicks or burrs. Chack all parts carafully for evidence of cracks or ‘conditions which cause subsequent oll leaks or failures, REASSEMBLY OF AXLE ‘The reassembly instructions describe the procedure to be followed when reassembling and installing components of axle. Instructions cover reassembly of only one sido of axla. Reassembly of opposite sida is identical uniass, otherwise noted, IMPORTANT: Both Grade 5 8 hardware have been used in the production of the: ale ‘assemblies covered in this manual, A table of proper torque ‘values for both Grade § and Grade @ hardware is provided ‘at the rear of this manual, Grade of hardware may be determined by the “hash” marks contained an the head of ‘gach bot; Grade § having three hash marks and Grade 8 having six hash marks a8 indicated on tabie of proper torque valve page, Torque values spocitied in toxt of this: manual are for Grade 8 hardware where presently used in production, Grade 5 torque values ate also specified when that grade hardware is presently used. On all axies being overhauled, bolts should be identified as described above and torque value chart consulted for correct torque. At reassembly apply threat Jocking compound where noted. ‘Guidelines for application where to apply A. On bolts, capscraws, and studs (anchor sn) apply ‘compound on female threaded component pa 1. Gn nate apply compound fe the male rtead ofthe mating fastener. C. Apply compound to coat the full length and circum- ference of thread engagement. D. Remove excess compound from mating parts alter festoner installation. =103-CORRECT ASSEMBLY OF DUO-CONE SEALS TERMINOLOGY ‘SEAL RING \ es’ TORIC HOUSING RETAINER LIP HOUSING RAMP SEAL RING HOUSING: SEAL RING FACE 7, SM. RING RAMP SEAL RING RETAINING LIP INSTALLATION TOOL THERE ARE FIVE FAILURE MODES 1. Oil Leakage 2. Galling 3. Pumping Mud Past The Torie 4, Toric Failure 5. Seal Ping Breakage Failures are caused by combinations of factors rather than one singla cause, but all have one ‘common denominator contributing to fellure— ASSEMBLY ERROR. STEP -1- INSTALL THE RU@BER TORIC ON THE SEAL RING ‘Toric must be on the bottam of the seal ring ramp. Make sure it is—STRAIGHT. SEAL RING FACE TORIC DON'T TWIST THE TORIC Handle seal ring carefully, Nicks and scratches on the seal ring face—CAUSE LEAKS. ‘STEP -2- REMOVE ANY OILY FILM FROM HOUSING AND SEAL RING RAMP, AND FROM THE TORIC Both ramps must be dry. Under no circumstances should oil from adjacent bearing installations or seal ring face lubrication ‘an the ramp or toric—UNTIL AFTER BOTH EAL RINGS ARE TOGETHER IN THEIR FINAL ASSEMBLED POSITION, ‘STEP -3- Wet toric in TriChloroethane to let it slip easily under the housing retainer tip: _——— DON'T USE STANOSOL OR ANY OTHER LIQUID THAT LEAVES AN OILY FILM OR DOES NOT EVAPORATE QUICKLY. STEP -4- Set seal rng with ore squarely onthe sual hous ing. APPLY sudden pressure to pop toric. under housing retaining lip. Toric can twist if itis dry on one spot or if there are burrs or fing on the housing retaining lip, A bulging toric or cocked seal can contribute to ‘eventual failure. =104-‘STEP -5- (CHECK WITH SIGHT GAGE Sight gage used te check variation in seal ring “assembled hoight.” Height variation around the assembied ring should not exceed .040" (1.0 MIM), INSTALLMENT —_ as; Make any required adjustments with installment tool— DO NOT PUSH DIRECTLY ON THE SEAL RING. BEFORE ASSEMBLING BOTH SEALS AND HOUSING TOGETHER... WAIT—at least two minutes to let all Tr. Chlorosthane evaporate (sorne may still be trap- ped between toric and housing ramp). 1. A wet spot between housing and ramp can cause sliding and cock the seal 2. Cocked seals cause uneven pressure on the seal face and it can cause the seal to wobble, ‘3 Uneven pressure causes leakage or scoring, 44. Wobbling seals can cause dint entry problems in the field. = 105 = ‘STEP -6- WIPE SEAL FACES ‘No foreign particles should be on the seal int faces. Something as small as a PAPER TOWE! RAVELING will hold the seal faces apart and cause leakage. ‘APPLY a thin film. of clean oil on the seal faces by using an applicator, disposable tissue, or a clean finger. STEP -7- FINALLY! ‘Assemble both housings and seal rings together. MAKE SURE THEY ARE SQUARE AND CONCENTRIC. Bring seals together slowly and carefully. Slam- ming can damage or break seal on impact. EXAMPLES CORRECT ASSEMBLYRESULTS OF INCORRECT ASSEMBLY ORIGINAL, ROTATED 180° FROM “AS ASSEMBLED" “ORIGINAL” POSITION there is low pressure ard porte Teokaye - 106 =— 107 ——108 ——109 —110 —s.* DRIV qsoieh Sine, > SPICER OFF-HIGHWAY PRODUCTS DIVISION Statesville, North Carolina Morganton, North Carolina Plymouth, Minnesota Brugge, Belgium ‘OHA-0003 PAINTED IN U.S.A,SPICER OFF-HIGHWAY PRODUCTS DIVISION Statesville, North Carolina Morganton, North Carolina Plymouth, Minnesota Brugge, Belgium Price on Request 559.905.0116 PRINTED IN U.S.A.