gears and thrust washers in the same manner.
b. Remove lock wire (17) and screws (21). Mark
Replace unserviceable parts. Replace washers as
the differential carrier bearing caps to assure
correct reassembly. Remove the bearing caps and
d. Inspect differential gear (4) for wear and
retaining rings (20).
damage to teeth. Replace worn or damaged gears.
c. Lift the differential and gear assembly from
e. Replace pinion if teeth are worn or
the carrier housing.
damaged,or if bearing surfaces are damaged.
d. Remove cotter pins (11), bolts (1), and nuts
f. Replace all oil seals and gaskets.
(10). Separate case halves (3), and remove gear
(4). Mark the case halves before separating
assure correct reassembly.
assembly as follows:
e. Remove gears (6) and washers (5). Remove
a. Install key (15) in shaft of pinion (14). Press
spider (9), gears (8), and washers (7). Remove
shaft into bevel gear (16) until gear is set firmly
bearings (2) using a suitable puller.
against shaft shoulder. Heat bevel gear in oil heater
to 200 to 250 F before installation.
bearing retainer (41) and attached parts from
b. Press bearing cones (13) on shaft of pinion
carrier housing. If retainer is not free, use a brass
drift to tap gear (16) on inner face of pinion or use
c. Lubricate bearing cones with light oil. Press
puller screws on retainer to remove it.
g. Remove gasket (33) and wire shim pack (34),
cups (121 into bearing retainers (27 and 62).
Install bearing retainer (66), with gasket (58) and
35, and 36) together to aid in adjustment and
shim pack (59, 60, and 61) on housing and secure
h. Remove cotter pin (51), and remove nut (52)
with nuts (181 and washers (19). Tighten nuts to a
torque of 116-149 foot-pounds.
and washer (53). Press bevel pinion gear (16) out
d. Install cross shaft assembly in housing and
of yoke (54) and retainer (41). Remove bearing
position bearing in bearing cap in retainer (62).
(37) from bevel pinion gear (16) with a suitable
Install bearing retainer (27), with gasket (31) and
i. Remove screws (48) and washers (47), and
shim pack (28, 29, and 301, on housing and secure
with nuts (26) and washers (25). Tighten nuts to a
remove cover (46) and gasket (45). Remove spacer
torque of 116-149 foot-pounds.
(39) and washer (55) from retainer (41). Press oil
e. Rotate cross shaft assembly a few times to
seal (44), bearing (43), and bearing cups (38 and
see that it is free in housing. Wrap a soft wire around
421 from retainer (41).
j. Remove nuts (18 and 26) and washers (19
pinion and attach a scale to wire. Check bearing
preload on scale. Preload should be 5 - 15 pounds.
and 25), and remove bearing retainers (27 and 62).
To adjust preload, add or remove shims under
Use puller screws to remove the bearing retainers.
bearing retainer (27).
k. Remove gaskets (31 and 58) and wire shim
f. Press bearing cone (37) on shaft of bevel
packs (28, 29, and 30, and 59, 60, and 61) together
gear (16). Press bearing caps (38 and 42) into bore of
to aid in adjustment and reassembly. Remove
bearing retainer (41). Lubricate bearing and cups
bearing cups (12) from bearing retainers.
with light oil.
l. Remove cross shaft gear assembly from
g. Install bevel gear (16) in bearing retainer
housing. Press bearings (13) and gear (16) from
(41). Install spacer (39) on shaft and press
pinion (14). Remove key (15) from pinion.
bearing (43) on shaft against spacer. Rotate
retainer around -haft several revolutions to assure
a. Clean all metal parts in dry cleaning solvent
normal bearing contact.
(Federal Specification P-S-661) and blow dry with
h. With shaft in press under pressure, check
bearing preload torque. Preload should be to 5 to 15
b. Clean bearings but do not blow dry with air.
pounds. To adjust torque, change spacer (39) as
c. Protect all bearings and machined surfaces
after cleaning by coating with a light coat of engine
i. Install oil seal (44) in retainer. Install gasket
(45) and cover (46) and secure with screws (48)
16-11. Inspection and Repair
and washers (47). Tighten screws to a torque of 53
a. Inspect all bearings, cones, and cup, and
to 67 foot-pounds.
replace if worn, pitted or damaged.
j. Press yoke (54) on shaft of bevel gear (16).
b. Inspect gears for wear or damage. Gears
Secure yoke with nut (52), washer (53), and
which are worn, ridged, pitted or scored must be
washer (55). Tighten nut to a torque of 81 to 104
c. Inspect differential case halves for worn,
k. Install gasket (33),' shim pack (34, 35, and
ridged, pitted, or scored surfaces. Inspect spiders,