Contents: Disassembly ⇩ Assembly ⇩
Disassembly
1.
NOTE: *This procedure applies to 110 and 130 models starting with the following VIN:
- 110 without ABS - 638164
- 110 Heavy Duty and 130, without ABS - 638224
- 110 Heavy Duty and 130, without ABS - 638134
Remove the differential assembly.
2. Secure the differential assembly in a vice or on a stand.
3. Knock out the cylindrical pins securing the adjusting nuts using the LRT 51-018/5 adjusting nut release tool.
4. Mark the bearing caps to facilitate assembly.
5. Unscrew the four bearing cap mounting bolts and remove the caps.
6. Remove the ring gear assembly and bearing outer races.
7. Mark the bearing outer races if the bearings are to be reused.
8. Using the LRT-51-003 tool to hold the pinion flange, remove the bolt and washer.
9.
Note: Older front differentials have a square flange and an additional spacer element. This remote element should be removed. On later versions of the front differential, there is a round flange, but there is no remote element.
Remove the final drive pinion flange.
10. Using a lever, remove the gear oil seal.
CAUTION: Be careful not to damage the oil seal groove.
11. Carefully remove the gear from the crankcase together with the rear bearing.
12. Remove the rear pinion bearing spacer and record the size of the spacer.
CAUTION: Do not discard the spacer at this stage.
13. Using a bearing puller, remove the front pinion bearing if it needs to be replaced.
14. Remove the front and rear bearing rings.
15. Remove the front pinion bearing adjusting shim and record the adjusting shim size.
16. Using a two-jaw puller and LRT 51-018/6, remove the differential bearings.
17. Clamp the ring gear assembly in a vice.
18. To facilitate assembly, mark the position of the crown gear relative to the holder.
19. Unscrew and discard the 10 bolts securing the crown gear to the holder.
20. Carefully remove the crown gear from the holder.
21. Mark the position of the differential housing to facilitate assembly.
22. Unscrew the 8 bolts securing the upper section of the differential housing and remove the housing.
23. Remove the upper sun gear and adjusting shim.
24. After marking their installation position, remove the satellites and axles. Remove the spherical washer from each satellite.
25. Remove the lower sun gear from the lower differential case section. Remove the adjusting shim.
26. Clean and inspect all components for wear and damage.
Assembly
1. Lubricate the sun gear, planet gears, spherical washers, adjusting shims and axles.
2. Install the adjusting shim onto the lower sun gear and install the sun gear onto the lower differential case section.
3. Install all pinions, axles and spherical washers into the lower section of the differential housing. Ensure that the pinions and axles are correctly secured.
4. Place the adjusting shim on the upper sun gear and position the upper sun gear relative to the planet gears to ensure proper engagement.
5. After aligning the reference marks on the differential housing, install the upper section of the differential housing. Screw in the bolts and tighten them gradually in a crisscross pattern to 32 Nm.
6. Install the crown gear on the planet carrier, ensuring that the reference marks are aligned. Screw in new bolts and gradually tighten them to 60 Nm.
7. Clean and remove any burrs from the original pinion front bearing adjusting shim. Install the adjusting shim into the recess in the bearing outer race.
8. Using LRT 51-018/3, install the front and rear bearing outer races.
9. Apply a thin layer of oil to the bearings.
10. Install the front bearing onto the pinion gear.
11. Install the gear into the gear housing and hold in place
12. Clean the original spacer and remove any burrs. Install it on the pinion shaft so that the groove in the spacer faces the drive flange. Press the spacer firmly against the front bearing of the pinion.
13. Install the rear pinion bearing.
14. Install the pinion flange, washer and bolt.
15. Use LRT-51-003 to hold the gear flange.
16. Tighten the pinion flange bolt to 100 Nm.
17. Check the gear for axial clearance. If the reading is zero.
18. Turn the gear several times to ensure that the bearings are in a stable position. Check the torque of the drive gear. The torque should be recorded when turning the gear. The torque of the drive gear should be 4 - 6 Nm.
19. Adjust the size of the spacer to obtain the correct turning torque (approx. 0.025mm = 1Nm).
NOTE: To increase turning torque, install a narrower spacer.
To reduce the turning moment, install a wider spacer.
20. Mount the LRT-51-018/7 tool on the flat plate, secure the DTI with the set screw and zero the DTI reading.
21. Ensure that the gear height adjustment block, indicator and mating surfaces are clean and free of any irregularities.
22. Install the LRT - 51018/2 adjustment block onto the gear head, correctly positioning it in the required position.
23. Pinion Height Adjustment Procedure: C = 'A' - 'B' Subtract nominal pinion height 'A' from adjusting block height 'B' (on the side of the adjustment block). Example: 76.04 - 74.7 = 1.34 mm. Therefore, the gear head height reading is 1.34 mm ±0.025 mm.
- 1. 'A' = Nominal pinion height, 76.04.
- 2. 'B' = Height of the adjustment block.
- 3. 'C' = Head height.
CAUTION: The height of the adjustment block should be checked against the numbers indicated on the side of the block.
24. Install the LRT -51-018-7 indicator on the adjustment block and rock it to obtain the minimum reading. If the reading is lower than required, reduce the size of the adjustment shim. If the reading is higher than required, increase the size of the adjustment shim.
25. Using the LRT-51-003 tool to hold the pinion flange, remove the bolt and washer. Remove the final drive pinion flange.
26. Remove the pinion gear, rear bearing and rear bearing spacer.
27. Remove the outer race and the adjusting shim of the front pinion bearing. Discard the adjusting shim. Clean the bearing ring recess and remove any burrs.
28. Install a shim of the required thickness and, using LRT 51-018/3, install the outer race of the front pinion bearing.
29. Install the pinion gear, spacer and pinion rear bearing.
30. Install the pinion flange, washer and bolt. Using LRT-51-003 to hold the pinion flange, tighten the bolt to 100 Nm.
31. Turn the gear in both directions to ensure that the bearings are in a stable position.
32. Check the gear turning torque again and adjust if necessary.
33. Check the pinion head height again.
34. Using the LRT-51-003 tool to hold the pinion flange, remove the bolt and washer. Remove the final drive pinion flange.
35. Discard the bolt.
36. Using tool LRT-51-009, install the pinion seal.
37. Install the spacer and rear bearing correctly.
38. Install the pinion gear, flange and washer.
39. Install the new pinion flange and tighten to 100 Nm.
40. Lightly lubricate the differential bearings.
41. Make sure the pins are located in the bearing caps.
42. Install the outer races of the differential bearings and install the differential assembly into the crankcase.
43. Install the bearing caps and tighten the bolts to 10 Nm.
44. Screw on the adjusting nuts, tighten the side nut of the crown gear to 22 Nm. Make sure that the opposite nut is loose.
45. Install the DTI to check the ring gear backlash. Adjust the opposite nut to obtain the correct ring gear backlash.
46. Turn the ring gear in both directions to ensure that the bearings are in a stable position.
47. Measure the side clearance of the crown gear in three positions and adjust if necessary.
NOTE: The ring gear side clearance should be within 0.076mm - 0.177mm.
48. Align the slots on the adjusting nuts with the nearest pin hole. Do not loosen the nuts to align.
49. Tighten the bearing cap bolts to 180 Nm.
50. Secure the adjusting nuts with new cylinder pins.
51. Apply special paint to the teeth of the ring gear to check the contact patch.
52.
NOTE: Apply assembly torque during cranking to check the contact patch. The total cranking torque should not exceed 10.85 Nm.
Rotate the gear several times to obtain a complete contact patch.
- 1. A = Torque side contact patch: This contact patch should be centered on the gear teeth. The coasting contact patch should be centered on the gear teeth, but may be offset toward the inner end of the tooth flank. There should be some clearance between the contact patch and the tooth tip.
- 2. B = Correct side clearance: Thinner shim required.
- 3. C = Correct side clearance: Thicker shim required.
- 4. D = Correct pinion shim: Reduce backlash.
- 5. E = Correct pinion shim: Increase side clearance.
53. Install the differential assembly.
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