n. To remove ring gear (69), remove nuts (67) and
differential side gear (60) in case half (58). Engage
holes in thrust washer on dowels projecting from thrust
washer bearing surface.
h. Apply coating of grease to spider (66) so that nee-
16-15. Cleaning, Inspection and Repair
dle rollers (64) can be assembled. Each spider leg
a. Clean all parts in cleaning solvent, Federal
should carry a double row of rollers (64), separated b,
Specification P-D-680, or equivalent, before inspection.
spacer (65) between rows and at the bottom of the leg
b. Replace all seals and packing.
Spacer (63) is installed on the end of the spider leg.
c. Inspect all rollers, cages and cups for wear, chip-
Slide pinion (62) into position and install thrust washer
ping and nicks. Do not replace a bearing cone or cup
(61) on the outside of pinion (62).
without replacing the mating cup or cone. After inspec-
i. Place the assembled pinion and spider in position
on the installed side gear. It is important that the tangs
lintless cloth or paper.
of the pinion thrust washers (61) engage their respec-
d. If possible, check all gears and shafts using the
tive grooves in the core halves.
magnaflux process. Examine teeth and ground and
j. Install remaining thrust washer (59) and side gear
polished surfaces for wear, pitting, chipping, nicks,
(60) in case half (57). Place the assembly on case half
cracks and scores. Replace all gears having cracked or
(58), making sure all thrust washers are properly
chipped teeth. Small nicks may be removed with a
seated and gear teeth are properly meshed. Be sure
matchmarks on the case halves are aligned. Install
e. Check differential pinions and side gears for signs
bolts (56) and nuts (55). Install oil tube (46) and dowel
of wear, chipping, cracks, and pitting. Differential
(52) in carrier (70). Press bearing cup (53) and oil re-
pinions and side gears must be replaced as a set.
tainer (49) in carrier.
Differential ring gear and pinion must also be replaced
k. For rear axle differential, omit paragraphs g
as a set if either is damaged.
through j above. Refer to figure 6-4 and assemble "no
f. Inspect carrier for cracks or conditions that could
spin" differential, items (59) through (65). Install the
cause subsequent oil leaks or failures. Check bearing
assembly in the ring gear case half assemble case
bores and seal seating surfaces for nick and burrs.
half (58) on the unit. Be sure match marks on case
halves are aligned. Install bolts (56) and nuts (55). It
stall oil tube (46) and dowel (52) in carrier (70). Press
a. Refer to figure 16-3. Press inner pinion bearing
bearing cup (53) and oil retainer (49) in carrier (70).
(45) on pinion (44). Stake pinion shaft in four places to
l. Install assembled bearing cage and pinion shaft in
retain the bearing, using a square end staking tool.
the carrier assembly. Do not install bearing cage shims.
b. Press center pinion bearing cone (47) onto pinion
Use four pinion oil seal retainer bolts with flat washers
shaft (44). Install spacer (42) and shim (40) on shaft
to pull pinion shaft assembly fully into the carrier. Be
(44). Press bearing cups (43) and (48) into pinion bear-
sure oil passages are aligned. Install three flat washers
ing cage (39).
on each bolt to prevent bottoming.
c. Position pinion bearing cage assembly on pinion
m. Use an inch-pound torque wrench to check bear-
shaft (44). Position outer bearing cone (35) on the shaft
ing preload at the pinion shaft. Preload should be be-
and press into place in bearing cup (43).
tween 13 and 23 in-lb (1.--2.6 N -m). Add or remove
d. Hold pinion cage assembly in a press, pinion end
shims (41) to attain proper preload. When proper
down, with approximately 500 pounds pressure on the
preload is attained, remove temporary bolts used to
bearing drive. Wrap several turns of soft wire or cord
hold bearing cage to housing. Install oil seal (40).
around the pinion cage. Pull the cord in a straight line
n. Install screws (37) and (38) and lock wire (36) the
with a spring scale. Read the scale while the cage ro-
screws in position. Install pinion drive gear (34),
tates. Multiply scale reading by one-half the diameter
washer (33) and nut (32). Tighten nut (32). Install cot-
of the bearing cage. Preload torque should be between
ter pin (31).
13 and 23 in-lb (1.--2.6 N - m). If preload is not cor-
o. Position the carrier and pinion shaft assembly in
rect, add shims to increase preload. Remove shims to
the differential stand so that the pinion shaft is down.
Insert a steel bar through the differential case halver
to facilitate handling. Position the differential into the
This is only a preliminary preload check.
carrier. Position differential bearing cups (8) and ad-
e. Press bearing cones (54) onto case half (58) and
justing nuts (7), one set at a time by lifting the alter-
case half (57). Check ring gear mounting surface of
nate sides of the steel bar.
flanged case half (54) for burr. Burrs may be removed
with a file.
f. Install ring gear (69) on flanged case half (58).
If bearing cones (54) were replaced, new bear-
Secure with bolts (68) and nuts (67).
ing cups (8) should also be replaced.
g. Lubricate and install thrust washer (59) and