2. Shutdown SIS
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Product: MOTOR GRADER
Model: 120M MOTOR GRADER B9N
Configuration: 120M Motor Grader B9N00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
12M and 120M Motor Graders Power Train
Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017
i03096382
Rear Axle, Differential and Final Drive - Disassemble
SMCS - 3258-015; 3278-015; 3282-015-RE; 4050-015; 4068-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 4
B 140-7742 Sleeve 2
C 1U-9200 Lever Puller Hoist 1
D 154-6182 Forcing Bolt 3
E 138-7574 Link Bracket 2
F
8B-7551 Bearing Puller Gp 1
1P-5546 Crossarm 1
3H-0465 Push-Puller Plate 2
5F-7366 Forcing Screw 1
G 292-4949 Socket Wrench As 1
H 154-6183 Forcing Bolt 3
J 1U-6405 Three Jaw Puller 1
Start By:
a. Remove the rear axle, differential, and final drive. Refer to Disassembly and Assembly,
"Rear Axle, Differential, and Final Drive - Remove".
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3. NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Inspect the O-ring seals. Replace the O-ring seals that are worn or damaged.
Illustration 1 g01413868
1. Use Tooling (A), Tooling (B), and two suitable lifting devices in order to position rear axle,
differential, and final drive (1) onto suitable blocking. The weight of rear axle, differential,
and final drive (1) is approximately 1089 kg (2400 lb).
Illustration 2 g01418559
2. Remove bolts (3), retainer (4), shims (5), sprocket (2), and sprocket (6).
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4. Note: Note the quantity and the order of shims (5).
Illustration 3 g01414357
3. Remove bearing cone (7).
Illustration 4 g01412778
4. Attach Tooling (A), Tooling (C), and two suitable lifting devices onto final drive housing
(8). The weight of final drive housing (8) is approximately 181 kg (400 lb). Remove nuts
(9).
5. Use Tooling (D) in order to remove final drive housing (8).
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5. Illustration 5 g01419912
6. Remove bolts (10). Remove retainer (11).
Illustration 6 g01352280
7. Remove shims (12). Use Tooling (A) and a suitable lifting device in order to remove
housing (13). The weight of housing (13) is approximately 57 kg (126 lb).
Note: Note the quantity and the order of shims (12).
Illustration 7 g01352292
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6. 8. Remove thrust washer (14). Remove wear sleeves (15).
Illustration 8 g01352299
9. Turn over housing (13). Remove lip seal (16).
Illustration 9 g01414353
10. Remove bearing cup (17). Remove thrust washer (18).
Illustration 10 g01352320
11. Remove lip seal (19). Remove bearing cup (20).
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7. Illustration 11 g01419983
12. Use Tooling (E) in order to remove carrier assembly (21) and drive shaft (22). The weight
of carrier assembly (21) and drive shaft (22) is approximately 58 kg (128 lb).
Illustration 12 g01419985
13. Use Tooling (F) in order to remove bearing cone (23).
Illustration 13 g01352339
14. Remove retaining ring (24) in order to remove axle shaft (22) from carrier assembly (21).
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8. Illustration 14 g01352406
15. Remove bolts (25) and retainer (26). Remove pin (27). Remove gear (28). Remove thrust
washers (29) and bearings (30). Repeat this step for the remaining planetary gears.
Illustration 15 g01352384
16. Remove axle shaft assembly (31).
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9. Illustration 16 g01352402
17. Remove retaining ring (32) in order to remove gear (33) from axle shaft (34).
Illustration 17 g01352438
18. Use Tooling (D) in order to separate ring gear (35) from the intermediate housing.
Illustration 18 g01352445
19. Use Tooling (B) and a suitable lifting device in order to remove ring gear (35). The weight
of ring gear (35) is approximately 23 kg (51 lb).
20. Repeat Step 2 through Step 19 for the opposite side.
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10. Illustration 19 g01353587
21. Position differential housing (36) with intermediate housing (37) upward.
Illustration 20 g01419994
22. Attach a suitable lifting device onto pinion (38). Use Tooling (H) in order to separate pinion
(38) from the center housing. Remove bolts (39) in order to remove pinion (38). The weight
of pinion (38) is approximately 47 kg (104 lb).
Illustration 21 g01353021
23. Remove shims (40). Remove O-ring seal (41).
Note: Note the order and the quantity of shims (40).
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11. Illustration 22 g01353002
24. Remove bolt (42). Remove retainer (43). Remove yoke (44). Remove guard (45).
Illustration 23 g01353512
25. Remove shims (46). Remove lip seal (47).
Note: Note the order and the quantity of shims (46).
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12. Illustration 24 g01353570
26. Remove pinion (48). Remove bearing cone (49). Remove bearing cup (50). Remove bearing
cone (51). Remove bearing cup (52).
Illustration 25 g01420086
27. Remove bolts (53).
Illustration 26 g01419995
Typical Example
28. Use Tooling (G) in order to remove nut assembly (54).
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13. Illustration 27 g01420082
29. Remove bolts (55). Remove bolts (56).
Illustration 28 g01419996
30. Use Tooling (H) in order to separate intermediate housing (37) from differential housing
(36).
Illustration 29 g01420124
31. Use Tooling (E) in order to remove intermediate housing (37). The weight of intermediate
housing (37) is approximately 31 kg (68 lb).
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14. Illustration 30 g01352893
32. Remove shims (57).
Illustration 31 g01352898
33. Use Tooling (A) in order to remove bearing assembly (58) and differential (59). The weight
of bearing assembly (58) and differential (59) is approximately 91 kg (200 lb).
Illustration 32 g01352982
34. Remove bolts (60). Remove shroud (61).
Illustration 33 g01419997
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15. 35. Use Tooling (F) in order to remove bearing assembly (62).
Illustration 34 g01354900
36. Remove bearing cone (63). Remove bearing cups (64).
Illustration 35 g01420000
37. Use Tooling (J) in order to remove spacer (65) and bearing cone (66).
Note: This step is a destructive procedure. Replace bearing cone (66).
Illustration 36 g01353751
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16. 38. Remove retaining ring (67). Remove bearing race (68). Remove O-ring seals (69). Remove
thrust ring (70).
Illustration 37 g01353760
Typical Example
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
39. Remove bolts (71). Remove case (72).
Illustration 38 g01353766
40. Remove thrust washer (73). Remove plates (74) and discs (75). Remove springs (76).
Note: Note the quantity and the order of plates (74) and discs (75).
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17. Illustration 39 g01353940
41. Use two people in order to remove housing (77). The weight of housing (77) is
approximately 23 kg (50 lb).
Illustration 40 g01353944
42. Remove differential gear (78).
Illustration 41 g01353945
43. Remove spider assembly (79).
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18. Illustration 42 g01353954
44. Remove thrust washer (80), pinion gear (81), and bearing sleeve (82) from spider (83).
Repeat this step for the remaining pinion gears (81).
Illustration 43 g01353965
45. Remove differential gear (84). Remove thrust washer (85).
Illustration 44 g01353970
46. Use two people in order to turn over housing (86) and bevel gear (87). Remove bolts (88).
The weight of housing (86) and bevel gear (87) is approximately 40 kg (88 lb). Remove
bolts (88). Use two people in order to remove housing (86) from bevel gear (87). The
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19. weight of housing (86) is approximately 23 kg (50 lb). The weight of bevel gear (85) is
approximately 17 kg (38 lb).
Illustration 45 g01355203
47. Remove bearing assembly (89). Remove piston (90).
Illustration 46 g01355208
48. Remove thrust race (91), thrust bearing (92), and thrust race (93) from piston (90).
Illustration 47 g01355211
49. Remove seals (94) from piston (90).
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20. Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 120M MOTOR GRADER B9N
Configuration: 120M Motor Grader B9N00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
12M and 120M Motor Graders Power Train
Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017
i07285127
Rear Axle, Differential and Final Drive - Assemble
SMCS - 3258-016; 3278-016; 3282-016-RE; 4050-016; 4068-016
Assembly Procedure
Table 1
Required Tools
Tool
Part
Number
Part Description Qty
A 439-3940 Link Bracket 4
B 140-7742 Sleeve 2
C 386-6031 Lever Puller Hoist 1
E 143-3939 Link Bracket 2
G 292-4949 Socket Wrench As 1
H 154-6183 Forcing Bolt 2
K 4C-4030 Thread Lock Compound 1
L 1U-8846 Gasket Sealant 1
M
6V-2012 Depth Micrometer 1
367-9109 Caliper(1)
1
N
8T-5096 Dial Indicator Gp 1
301-3405 Gauge 1
P 8T-4140 Bolt 4
R 7M-7456 Bearing Mount Compound 1
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21. S - Cat Advance 3Moly Grease or Dow Corning Molykote BR2 -
Plus
1
T 8T-5096 Dial Indicator Gp 1
(1)
For use with three bolt retainers
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Inspect the O-ring seals, gaskets, and lip seals. Replace O-ring seals, gaskets, and lip seals
that are worn or damaged.
Note: Lubricate O-ring seals and lip seals with the lubricant that is being sealed.
Illustration 1 g03831520
1. Install seals (94) onto piston (90).
Illustration 2 g03831488
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22. Note: Grease is used to hold thrust race (93) and thrust bearing (92) in place during
assembly.
2. Apply a liberal amount of grease to thrust race (93) and to thrust bearing (92). Install thrust
race (93) and thrust bearing (92) onto piston (90).
Illustration 3 g01355203
3. Install piston (90). Lower the temperature of bearing assembly (89). Install bearing
assembly (89).
Illustration 4 g01353970
4. Use two people to install housing (86) onto bevel gear (87). The weight of housing (86) is
approximately 41 kg (90 lb). Install bolts (88). Tighten bolts (88) to a torque of
300 ± 40 N·m (221 ± 30 lb ft).
5. Use two people to turn over bevel gear (87) and housing (86). The combined weight of
bevel gear (87) and housing (86) is approximately 59 kg (130 lb).
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23. Illustration 5 g01353965
6. Install thrust washer (85). Install differential gear (84).
Note: Install thrust washer (85) with the groove side against gear (84).
Illustration 6 g01353954
7. Install bearing sleeve (82), pinion gear (81), and thrust washer (80) onto spider (83). Repeat
this step for the remaining pinion gears (81).
Illustration 7 g01353945
8. Install spider assembly (79).
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24. Illustration 8 g01353944
9. Install differential gear (78).
Illustration 9 g01353940
10. Install housing (77).
Note: Ensure that the notches on the housings are aligned.
Illustration 10 g01353766
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26. 11. Install plates (74) and discs (75). Install thrust washer (73). Install springs (76).
Note: Lubricate the discs with the lubricant that is being sealed.
Note: Install thrust washer (73) with the groove side against the gear.
Illustration 11 g01353760
Typical Example
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
Note: Determine bolt size before torquing bolts (71).
12. Install case (72). Install bolts (71). Tighten M16 bolts (71) to a torque of 300 ± 40 N·m
(220 ± 30 lb ft). Tighten M12 bolts (71) to a torque of 120 ± 20 N·m (90 ± 15 ft)
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27. Illustration 12 g03831494
Note: Grease is used to hold thrust race (91) in place during assembly.
13. Install thrust ring (70). Apply a liberal amount of grease to thrust race (91). Install thrust
race (91) onto thrust ring (70). Install O-ring seals (69). Raise the temperature of bearing
race (68). Install bearing race (68). Install retaining ring (67).
Illustration 13 g01354921
14. Raise the temperature of bearing cone (66). Install bearing cone (66) and spacer (65).
Illustration 14 g06240309
15. Use a suitable press to install bearing assembly (55). Install shroud (58). Apply Tooling (K)
to the threads of bolts (57) and install bolts (57). Tighten bolts (57) to a torque of
28 ± 7 N·m (21 ± 5 lb ft).
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