This document provides repair procedures for differentials. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, disassemble the differential assembly into its main components, and remove the drive pinion and pinion carrier from the differential carrier. Detailed steps are provided for removing parts like the bearing caps, ring gear, side gears, and pinion gears. Safety warnings and cautions are also given throughout.
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This document provides repair procedures for differentials used in H400HD, H400HDS, H450HD, and H450HDS lift trucks. It describes the components of a typical differential assembly and provides step-by-step instructions for removing the differential carrier from the axle housing, removing the differential and ring gear from the carrier, and removing the drive pinion and pinion carrier. It also gives directions for disassembling the differential and ring gear assembly. Specifications and troubleshooting information are provided at the end.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The document includes warnings and cautions for the repair procedures.
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This document provides descriptions and repair procedures for differentials. It describes the main components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly.
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This document provides repair procedures for differentials. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are also included to take apart the differential and ring gear assembly and disassemble the drive pinion and pinion carrier.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The summary is provided in 3 sentences or less as requested.
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This document provides repair procedures for differentials used in H300HD, H330HD, H360HD, and H360HD-EC lift trucks. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the ring gear and differential from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are provided to take apart the differential case halves and related components. Specifications and troubleshooting information are also referenced.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The document includes warnings and cautions for safe repair.
Hyster f019 (h360 hd ec) forklift service repair manualfksjksmmde
This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The summary is provided in 3 sentences or less as requested.
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This document provides repair procedures for differentials used in H400HD, H400HDS, H450HD, and H450HDS lift trucks. It describes the components of a typical differential assembly and provides step-by-step instructions for removing the differential carrier from the axle housing, removing the differential and ring gear from the carrier, and removing the drive pinion and pinion carrier. It also gives directions for disassembling the differential and ring gear assembly. Specifications and troubleshooting information are provided at the end.
Hyster f019 (h360 hd ec) forklift service repair manualfujsjefjksekfsmem
This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The document includes warnings and cautions for the repair procedures.
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This document provides descriptions and repair procedures for differentials. It describes the main components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly.
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This document provides repair procedures for differentials. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are also included to take apart the differential and ring gear assembly and disassemble the drive pinion and pinion carrier.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The summary is provided in 3 sentences or less as requested.
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This document provides repair procedures for differentials used in H300HD, H330HD, H360HD, and H360HD-EC lift trucks. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the ring gear and differential from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are provided to take apart the differential case halves and related components. Specifications and troubleshooting information are also referenced.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The document includes warnings and cautions for safe repair.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The summary is provided in 3 sentences or less as requested.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Safety warnings and cautions are provided throughout.
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This document provides repair procedures for differentials used in H300HD, H330HD, H360HD, and H360HD-EC lift trucks. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the ring gear and differential from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are provided to take apart the differential case halves and related components. Specifications and troubleshooting information are also referenced.
Hyster f019 (h360 hd) forklift service repair manualpfiskdmjekm
This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Safety warnings and cautions are provided throughout.
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This document provides repair procedures for differentials used in H300HD, H330HD, H360HD, and H360HD-EC lift trucks. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the ring gear and differential from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are provided to take apart the differential case halves and related components. Specifications and troubleshooting information are also referenced.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The document includes warnings and cautions for the repair procedures.
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This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier. The summary is provided in 3 sentences or less as requested.
Hyster a917 (h44.00 xm 12 europe) forklift service repair manualjfksekmmdme
This document provides descriptions and repair procedures for differentials. It describes the main components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly.
Hyster a917 (h40.00 xm 12 europe) forklift service repair manualfusjfjskekmem
This document provides descriptions and repair procedures for differentials. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The differential permits the drive wheels to rotate at different speeds during a turn. The document outlines steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also provides instructions for disassembling the differential and ring gear assembly and disassembling the drive pinion and pinion carrier.
Hyster a917 (h44.00 xm 12 europe) forklift service repair manualfjjskekdmmem
This document provides descriptions and repair procedures for differentials. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The repair procedures cover removing the differential carrier from the axle housing, removing the differential and ring gear from the carrier, and removing the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly and disassembling the drive pinion and pinion carrier.
Hyster a917 (h40.00 xm 12 europe) forklift service repair manualfjsekkdmme
This document provides descriptions and repair procedures for differentials. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The differential permits the drive wheels to rotate at different speeds during a turn. The document outlines steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also provides instructions for disassembling the differential and ring gear assembly and disassembling the drive pinion and pinion carrier.
Hyster a917 (h40.00 xm 12 europe) forklift service repair manualfusjejfskekemm
This document provides descriptions and repair procedures for differentials. It describes the typical components of a differential assembly, including the housing, ring and pinion gear set, and differential assembly. The repair procedures cover removing the differential carrier from the axle housing, removing the differential and ring gear from the carrier, and removing the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly and disassembling the drive pinion and pinion carrier.
Hyster a917 (h48.00 xm 12 europe) forklift service repair manualfjskekdmmem
This document provides descriptions and repair procedures for differentials. It describes the main components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures explain how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Detailed steps are provided for disassembling the differential and ring gear assembly.
Hyster f019 (h14.00 xm europe) forklift service repair manualfujsejfksekkme
This document provides repair procedures for differentials used in lift trucks. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. Disassembly steps are also provided to take apart the differential case halves. Safety warnings and cautions are included throughout.
Hyster f019 (h14.00 xm europe) forklift service repair manualfujjsefkskemm
This document provides repair procedures for differentials used in Europe. It describes the components of a typical differential assembly and provides step-by-step instructions to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and disassemble the differential assembly. Detailed diagrams and warnings are included to correctly and safely perform the repair work.
Hyster f019 (h16.00 xm europe) forklift service repair manualfujsjefjskekemm
This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the differential carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier.
Hyster f019 (h13.00 xm europe) forklift service repair manualfujsjefkksekmm
This document provides repair procedures for a differential assembly. It describes the components of a typical differential, including the housing, ring and pinion gear set, and differential assembly. It provides steps to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and remove the drive pinion and pinion carrier from the carrier. It also describes how to disassemble the differential and ring gear assembly and disassemble the drive pinion and pinion carrier.
Hyster f019 (h14.00 xm europe) forklift service repair manualfusjejkdkmse
This document provides repair procedures for differentials used in Europe. It describes the components of a typical differential assembly and provides step-by-step instructions to remove the differential carrier from the axle housing, remove the differential and ring gear from the carrier, and disassemble the differential assembly. Detailed photos illustrate the parts and procedures. Safety warnings are provided throughout regarding proper vehicle support and use of proper tools.
Hyster g006 (h7.00 xl europe) forklift service repair manualfjsekqazxkdmmem
This document provides repair procedures for a differential assembly. It describes removing the differential carrier from the axle housing, then removing the differential and ring gear from the carrier. It also describes removing the drive pinion and pinion carrier from the differential carrier. Detailed steps are provided to disassemble the differential case halves and related components. Specifications and troubleshooting information are referenced at the end.
Hyster g006 (h7.00 xl europe) forklift service repair manualfdujsjefjskekmsme
This document provides repair procedures for a differential assembly. It describes removing the differential carrier from the axle housing, then removing the differential and ring gear from the carrier. It also describes removing the drive pinion and pinion carrier from the differential carrier. Detailed steps are provided to disassemble the differential case halves. Specifications and troubleshooting information are listed at the end. Figures illustrate the typical differential assembly and parts.
Hyster g006 (h6.00 xl europe) forklift service repair manualufjjjsekkemm
This document provides repair procedures for differentials used in lift trucks. It describes the components of a typical differential assembly, including the housing, ring and pinion gear set, and differential assembly. The procedures describe how to remove the differential carrier from the axle housing, disassemble the differential assembly by removing the ring gear, spider, pinion gears and side gears. It also provides instructions for removing the drive pinion and pinion carrier from the differential carrier. The goal is to inspect and replace worn components before reassembling the differential.
New holland t4.80 f tractor service repair manualfsefkksefmme
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New holland ls190.b skid steer loader service repair manualfsefkksefmme
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2. 1400 SRM 46 Description
General
This section contains description and repair procedures for the differential. There is a Specifications section
and a Troubleshooting section at the end of this section.
Description
This differential is fastened to the drive axle hous-
ing of the lift truck. The differential provides a sin-
gle-speed reduction for an increase in torque to the
drive wheels. There is a housing, a ring and pinion
gear set, and the differential assembly. The ring gear
transfers power from the pinion through the differen-
tial assembly to the axles. The differential assembly
permits the drive wheels to rotate at different speeds
during a turn. See Figure 1.
Figure 1. Typical Differential Assembly
1
3. Differential Repair 1400 SRM 46
Legend for Figure 1
NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED.
1. PINION NUT
2. WASHER*
3. INPUT YOKE*
4. DEFLECTOR
5. TRIPLE-LIP OIL SEAL
6. DIFFERENTIAL CARRIER
7. FILL PLUG
8. ADJUSTMENT RING
9. LOCK PLATE
10. CAPSCREW
11. SIDE GEAR
12. THRUST WASHER
13. CASE HALF
14. BEARING CONE
15. BEARING CUP
16. PINION
17. SPIDER
18. CAPSCREW OR RIVET*
19. RING GEAR
20. CASE HALF, FLANGE
21. NUT*
22. NUT
23. WASHER
24. THRUST BLOCK*
25. BEARING CAP
26. COTTER PIN (ADJUSTING
RING)*
27. JAM NUT*
28. THRUST SCREW*
29. RETAINING RING
30. WASHER
31. SPIGOT BEARING
32. PINION
33. SPACER
34. SHIM
35. PINION CARRIER
36. COVER
37. BOLT
38. SHIFT FORK
39. SPRING
40. SHIFT SHAFT
41. PIN
42. AIR CYLINDER TUBE
43. SCREW IN DIFFERENTIAL
LOCK CYLINDER
44. CYLINDER COVER
45. GASKET
46. PLUG
47. SHIFT COLLAR
48. PISTON
49. O-RING
Differential Repair
REMOVE
NOTE: The repair procedures cover all units unless
otherwise indicated.
Differential Carrier From Axle Housing,
Remove
NOTE: The differential assembly can normally be
removed without removing the drive axle. On some
trucks, including the H7.00-12.50H (H150-275H),
the drive axle must be removed to remove the dif-
ferential assembly. If removal of the drive axle is
necessary, see the Drive Axle service manual for
your lift truck model.
1. Remove the mast. See the Mast section for your
lift truck model for the removal procedures.
2. Raise the end of the vehicle where the axle is
mounted. Use a jack or other lifting tool, and
place safety stands under each side of the axle.
See Figure 2.
WARNING
Block the wheels to prevent the lift truck
from moving. Support the lift truck with
safety stands. DO NOT work under a lift truck
supported only by jacks. Jacks can slip and
fall over. Serious personal injury can result.
3. Place jack stands under each spring seat of the
axle, to hold the lift truck in the raised position.
1. SAFETY STANDS
Figure 2. Lift Truck Support
2
4. 1400 SRM 46 Differential Repair
4. Remove plug from the bottom of the axle housing
and drain the oil from the axle assembly.
5. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove
the speed reducer or gear box.
6. Some units have a drum or disc brake attached to
the output yoke. Disconnect any brake linkage or
brake lines. See the Brake section for your unit.
7. Disconnect the driveline universal joint from the
pinion input yoke or flange on the differential
carrier. See Figure 3.
8. Remove the axle shafts from the axle housing.
See the Drive Axle section for your model of lift
truck for the procedures.
a. On Straddle Trucks™, disconnect the drive
axle universal joints at the differential
yokes. Remove the capscrews that fasten the
bearing retainers to the differential hous-
ing. Pull the yoke, stub shaft and bearing
retainer from the housing.
9. Place a transmission jack under the differential
carrier for support. See Figure 4.
1. BEARING CUPS
2. END YOKE
3. YOKE SADDLE
4. WELD YOKE
5. BEARING STRAP
6. CAPSCREWS
7. U-JOINT CROSS
8. SLIP YOKE
9. TUBING
Figure 3. Typical Driveline Universal Joint
3
5. Differential Repair 1400 SRM 46
1. WOOD BLOCK
2. TRANSMISSION JACK
3. CAPSCREWS
Figure 4. Differential Carrier Support
10. Remove all but the top two differential carrier
housing capscrews. See Figure 4.
11. Loosen the top two differential carrier housing
capscrews and leave them attached to the assem-
bly. The capscrews will hold the differential car-
rier in the housing.
12. Loosen the differential carrier in the axle hous-
ing. Use a leather mallet to hit the mounting
flange of the differential carrier at several points.
13. After the differential carrier is loosened, remove
the top two capscrews.
CAUTION
When using a pry bar, be careful not to dam-
age the differential carrier or housing flange.
Damage to these surfaces will cause oil leaks.
14. Remove the differential carrier from the axle
housing. Use a pry bar with a round end, to help
remove differential carrier from housing.
15. Remove the differential carrier assembly from
under the lift truck.
16. Use a lifting device and lift the differential car-
rier by the input yoke or flange and place the as-
sembly on a repair stand. See Figure 5.
1. DIFFERENTIAL CARRIER
2. REPAIR STAND
Figure 5. Differential Carrier Stand
Differential and Ring Gear From
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
NOTE: Before working on the differential carrier, in-
spect the hypoid gear set for damage. If inspection
shows no damage, the same gear set can be used
again. Measure the backlash of the gear set and
make a record of the dimension. See the section Ring
Gear Backlash, Adjust. During differential reassem-
bly, adjust the backlash to the original recorded di-
mension when the gear set is installed into the dif-
ferential carrier.
1. Loosen the jam nuts on the thrust screw.
2. Remove the thrust screw and jam nut from the
differential carrier. See Figure 6.
4
6. 1400 SRM 46 Differential Repair
Figure 6. Thrust Screw and Jam Nut Removal
3. Rotate the differential carrier until the ring gear
is at the top of the assembly.
4. Mark one differential carrier leg and bearing cap
to correctly match the parts during differential
carrier assembly. Mark the parts using a center
punch and hammer. See Figure 7.
1. BEARING CAP
2. DIFFERENTIAL CARRIER LEG
3. MATCHMARKS
Figure 7. Mark Differential Carrier Leg and
Bearing Cap
5. Remove the cotter pins that hold the bearing ad-
justing rings in position. Some differential car-
rier models have dowel pins or lock plates hold-
ing the bearing adjusting rings in position. Each
lock plate is held in position by two capscrews.
See Figure 8.
6. Remove capscrews and washers holding the two
bearing caps on the differential carrier. See Fig-
ure 8.
1. COTTER PIN 2. LOCK PLATE
Figure 8. Bearing Adjusting Ring Removal
7. Remove the bearing caps and bearing adjusting
rings from the differential carrier. See Figure 9.
5
7. Differential Repair 1400 SRM 46
1. BEARING CAP
2. BEARING ADJUSTING RING
Figure 9. Bearing Cap Removal
8. Use a lifting device and lift the main differential
and ring gear assembly from the differential car-
rier. See Figure 10.
1. BEARING CUP
2. DIFFERENTIAL CARRIER
3. BEARING BORE
4. PUT ADHESIVE HERE (INSTALLATION ONLY)
Figure 10. Main Differential and Ring Gear
Assembly Removal
Drive Pinion and Pinion Carrier From
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Fasten a yoke or flange bar to the input yoke or
flange. When the nut is removed, the bar will
hold the drive pinion in position. See Figure 11.
2. Remove the nut and washer from the drive pin-
ion.
3. Remove the yoke or flange bar.
1. FLANGE BAR 2. YOKE BAR
Figure 11. Flange and Yoke Bar
CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mal-
let can damage the parts and cause driveline
runout or driveline imbalance problems after
carrier to driveline assembly.
4. Remove the yoke or flange from the drive pinion.
If the yoke or flange is tight on the pinion, use a
puller for removal. See Figure 12.
5. Remove the capscrews and washers that hold the
pinion carrier in the differential carrier. See Fig-
ure 13.
6
8. 1400 SRM 46 Differential Repair
A. YOKE PULLER B. FLANGE PULLER
Figure 12. Yoke and Flange Puller Tools
1. DRIVE PINION AND PINION CARRIER
2. SHIMS
3. CAPSCREWS
Figure 13. Pinion Carrier Removal
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
CAUTION
Do not use a pry bar to remove the pinion car-
rier from the carrier. A pry bar can damage the
bearing case, shims, and differential carrier.
6. Remove the drive pinion, pinion carrier, and
shims from the differential carrier. See Fig-
ure 13. If the pinion carrier is tight on the
differential carrier, hit the pinion carrier at sev-
eral points around the flange area with a leather,
plastic or rubber mallet.
7. Inspect the shims. If they are in good condition,
keep the shims together for use during differen-
tial carrier assembly.
8. If the shims are to be replaced, first measure the
total thickness of the pack. Make a note of the
dimension. The dimension will be needed to cal-
culate the depth of the drive pinion in the differ-
ential carrier when the gear set is installed.
DISASSEMBLE
Differential and Ring Gear Assembly,
Disassemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
NOTE: Make sure there are matching marks on the
case halves of the differential assembly. See Step 4
in the section Differential and Ring Gear From Dif-
ferential Carrier, Remove. See Figure 7.
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
1. Remove the capscrews and washers that hold
the case halves together and separate the case
halves. If necessary, use a brass, plastic, or
leather mallet to loosen the parts.
7
9. Differential Repair 1400 SRM 46
2. Remove the differential spider, four pinion gears,
two side gears, and six thrust washers from in-
side the case halves. See Figure 14.
1. THRUST WASHER
2. SIDE GEAR
3. SPIDER, PINIONS, AND THRUST WASHERS
Figure 14. Ring Gear Disassembly
3. If the ring gear needs to be replaced, remove
bolts, nuts, and washers holding the ring gear to
the flange case half.
CAUTION
Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case. See Figure 15.
4. If your differential model uses rivets to hold the
ring gear to the flange case half, remove the riv-
ets as follows:
a. Center punch each rivet head in the center,
on the ring gear side of the assembly.
b. Drill each rivet head on the ring gear side of
the assembly to a depth equal to the thick-
ness of one rivet head. Use a drill bit that is
1/32 of an inch smaller than the body diame-
ter of the rivets. See Figure 15.
c. Press the rivets through holes in the ring
gear and flange case half. Press from the
drilled rivet head.
A. CORRECT DRILLING RIVETS FROM HEAD
B. WRONG CHISELING RIVETS FROM HEAD
Figure 15. Rivet Removal
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
5. Separate the case half and ring gear using a
press. Support the assembly under the ring gear
with metal or wood blocks and press the case
half through the gear. See Figure 16.
1. CASE HALF
2. PRESS
3. PLATE
4. SUPPORTS
Figure 16. Case Half and Ring Gear Separation
8
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11. 1400 SRM 46 Differential Repair
6. If the differential bearings need to be replaced,
remove the bearing cones from the case halves.
Use a bearing puller or press. See Figure 17.
A. PULLER B. PRESS
Figure 17. Differential Bearings Replacement
Drive Pinion and Pinion Carrier,
Disassemble
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Place drive pinion and pinion carrier in a press.
The pinion shaft must be toward the top of the
assembly. Add supports for the pinion carrier
under the flange area. See Figure 18.
2. Press the drive pinion through the pinion carrier.
See Figure 18.
1. PRESS
2. DRIVE PINION
3. OIL SEAL
4. PINION CARRIER
5. SUPPORT
6. SPIGOT BEARING
7. FLANGE SUPPORT
Figure 18. Drive Pinion Disassembly
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
NOTE: The inner bearing cone and bearing spacer
will remain on the pinion shaft. See Figure 19.
3. If a press is not available, use a leather, plastic
or rubber mallet to drive the pinion through the
pinion carrier.
CAUTION
When removing the oil seal, Do not damage the
wall of the bore. Damage to the bore wall can
result in oil leaks.
NOTE: Always replace the oil seal with a new seal
during reassembly.
4. Remove the oil seal from the pinion carrier. See
Figure 19.
9
12. Differential Repair 1400 SRM 46
1. DRIVE PINION
2. OIL SEAL
3. OUTER BEARING (CUP AND CONE)
4. INNER BEARING (CUP AND CONE)
5. SPIGOT BEARING
6. SNAP RING
7. BEARING SPACER
Figure 19. Drive Pinion
5. Inspect the pinion bearings and replace if neces-
sary. If the pinion bearings need to be replaced,
perform the following:
a. Remove the inner and outer bearing cups
from the inside of the cage. Use either a press
and sleeve, bearing puller, or a small drift
pin. See Figure 17 and Figure 20. If a press
is used, provide support for the pinion car-
rier under the flange area with metal or wood
blocks.
CAUTION
The puller must fit under the inner race of
the cone to remove the cone correctly without
damage.
b. Remove the inner bearing cone from the
drive pinion with a press or bearing puller.
See Figure 21.
6. If the spigot bearing needs to be replaced, place
the drive pinion in a vise. Install a soft metal
cover over each vise jaw to protect the drive pin-
ion.
7. Remove the snap ring from the end of the drive
pinion. See Figure 22.
NOTE: Some spigot bearings are fastened to the drive
pinion with a special peening tool. See Figure 23.
NOTE: Some spigot bearings are a two-piece assem-
bly. Remove the inner race from the pinion with a
bearing puller. Remove the outer race/roller assem-
bly from the pinion carrier with a drift or a press. See
Figure 24.
8. Remove the spigot bearing from the drive pinion
with a bearing puller.
A. BEARING DRIVER B. BEARING PULLER
Figure 20. Pinion Bearing Replacement
10
14. Differential Repair 1400 SRM 46
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean and inspect the following parts of the differen-
tial:
• Yoke- Clean the surface of the yoke journal with a
cleaning solvent and inspect the original yoke seal
surface for any grooves.
• Drive axle- Clean the parts of the axle with sol-
vent and dry with compressed air. Inspect all ma-
chined surfaces and bearings for wear and damage.
• Tapered Roller Bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
• Pinions and Gears- Inspect the pinions and gears
for wear or damage. Gears that are worn or dam-
aged must be replaced.
• Axle shafts- Inspect the axle shafts for wear and
cracks at the flange, shaft and splines. If axle
shafts show signs of wear or damage, replace the
axle shafts.
• Main differential assembly- Inspect all parts of
the main differential assembly for wear or damage.
Parts that are damaged must be replaced. See Fig-
ure 25 for parts to inspect.
A. DIFFERENTIAL CASE HALVES
B. DIFFERENTIAL GEAR NEST ASSEMBLY
1. INSPECT INSIDE SURFACES
2. PINION AND THRUST WASHER
3. SIDE GEAR AND THRUST WASHER
4. SPIDER
Figure 25. Main Differential Assembly
Inspection
12
15. 1400 SRM 46 Differential Repair
ASSEMBLE
Pinion, Bearings, and Pinion Carrier,
Assemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Put differential oil on the bearings and cups. In-
stall the cups in the pinion carrier. See Figure 1.
2. Install the inner bearing and spigot bearing
against the pinion shoulders. Use a sleeve and
press to push against the inner bearing race.
CAUTION
If a new pinion is installed, a new ring gear
must also be installed. The pinion and ring
gear are a set (see Figure 32) and must be in-
stalled together.
NOTE: During assembly at the factory, one spacer is
used. Two thinner spacers are used if the pinion or
bearings are replaced. These spacers are selected for
correct bearing preload.
NOTE: Some spigot bearings are fastened to the pin-
ion with a snap ring, and some are fastened with a
punch. Others can have a two-piece bearing. See Fig-
ure 24.
3. Install the spigot bearing washer and snap ring.
Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion. See Figure 19.
4. Use a press to install the outer bearing against
the spacer. Rotate the carrier to make sure the
bearings are installed correctly.
5. Use either the Press Method or the Yoke or
Flange Method, and apply the correct preload.
See Specifications, Table 6. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
Pinion Bearings, Adjust Preload
Press Method
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: If a press is not available, or the press does
not have a pressure gauge, use the Yoke or Flange
Method to adjust pinion bearing preload.
1. Place the drive pinion and carrier assembly in a
press with the gear head (teeth) toward the bot-
tom.
2. Install a sleeve of the correct size against the in-
ner race of the outer bearing. See Figure 19.
3. Apply and hold the correct amount of pressure to
the pinion bearings. See Specifications, Table 6.
As pressure is applied, rotate the pinion carrier
several times so that the bearings make normal
contact.
4. While pressure is held against the assembly,
wrap a cord several times around the pinion
carrier. Fasten a Newton or pound scale to the
cord. See Figure 26.
1. PRESS
2. SLEEVE
3. PINION BEARING
Figure 26. Bearing Preload Check
13