10/1/23, 9:01 SIS 2.

2003/10/01 Differential And Carrier Assembly (Standard) (Later) 3258-015 (SENR2769-01)

SMCS - 3258 SENR27690021

Disassemble Differential And Carrier Assembly (Standard)

(Later)
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START BY:

a. remove differential and carrier assembly

1. Put differential and carrier assembly (3) in position on tooling (A) with the bevel gear down as shown.

2. Remove the bolts and retainer (1) from pinion housing (2).

3. Remove lip-type seal (4) from retainer (1).

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4. Fasten tooling (B) and a hoist to pinion housing (5) as shown.

5. Remove the bolts that hold pinion housing (5) to the carrier assembly.

6. Use two 1/2"-13 NC forcing screws (6) to loosen pinion housing (5) from the carrier housing. Remove housing (5) and pinion from the carrier
assembly. The weight of the pinion housing and pinion is 32 kg (70 lb.).

7. Remove the O-ring seal from the pinion housing.

8. Use tool (C), and remove the staked portion of nut (8) from the groove (slot) in pinion shaft (7) as shown.

9. Use tool (D), and remove nut (8) from the pinion shaft.

10. Remove washer (9) from pinion shaft (7).

NOTICE

Do not let pinion shaft assembly (7) fall when it is pushed out of
pinion housing (5).

11. Use a press to push pinion shaft assembly (7) out of the pinion housing.

12. Remove bearing cone (10) from the pinion housing.

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NOTICE

Do not let pinion shaft (7) fall when it is pushed out of the
bearing cone.

13. Use a press and tooling (E) to push pinion shaft (7) out of the bearing cup.

14. If necessary, use tooling (F) to remove the bearing cups from each end of pinion housing (5) as shown.

15. Turn the carrier assembly with tooling (A) until the bevel gear is up as shown.

16. Remove bolts (12) and locks (14) from bearing cups (11) and (16).

17. Loosen bolts (13) that hold the bearing caps; then loosen nuts (15) approximately 1/2turn to make the removal of the differential from the carrier
assembly easier.

18. Remove bolts (13) and bearing caps (11) and (16) from the carrier assembly.

19. Put a bar or piece of pipe through the center of the differential assembly. Fasten a nylon strap and a hoist to the bar or pipe as shown.

20. Remove differential assembly (17) from carrier assembly (18). The weight of the differential assembly is 52 kg (115 lb.).

21. Remove nuts (20) and bearing cones (19) from the differential assembly.

22. Use tooling (G) to remove bearing cone (21) from the differential.

NOTE: Put alignment marks on case (22) and (24) for use at assembly.

23. Remove 12 bolts (23) and case (22) from case (24).

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24. Remove washer (24) from gear (25). Remove gear (25) from the spider gears.

25. Remove the spider assembly from the differential case.

26. Remove washers (28) and spider gears (27) from spider (26).

27. Remove gear (29) and the washer under it from case (24).

28. Put bevel gear (31) and case (24) in position on wooden blocks as shown.

29. Remove bolts ((30) that hold case (24) to bevel gear (31). Use two persons, and remove case (24) from the bevel gear. The weight of the bevel
gear is approximately 23 kg (50 lb.).

30. Use tooling (G) to remove bearing cone (32) from case (24).

Assemble Differential And Carrier Assembly (Standard) (Later)

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1. Lower the temperature of bearing cups (1), and install them in each end of pinion housing (2). The bearing cups must be against (seated) the
shoulder in housing (2).

2. Heat bearing cone (4) to a maximum temperature of 135°C (275°F), and install it on pinion shaft (3). The bearing cone must be against (seated)
the shoulder on pinion shaft (3).

3. After bearing cone (4) has cooled, put clean differential oil on it.

NOTE: There must be a small amount of end play in the bearings after bearing (5) is installed in housing (2).

4. Heat bearing cone (5) to a maximum temperature of 135°C (275°F), and install it on the pinion shaft until it is against (seated) the bearing cup in
the housing.

5. After bearing cone (5) has cooled, put clean differential oil on it.

6. Install washer (7) on the pinion shaft with the tab of the washer engaged in the groove (slot) of the shaft.

7. Install nut (6) until it just makes contact with washer (7).

8. Put pinion housing assembly (2) in position in a soft jawed vise. Tighten the vise against the gear teeth of pinion shaft (3) as shown.

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9. While pinion housing (2) is turned slowly, tighten a nut (6) with tool (C) and an air impact wrench until a slight resistance is required to rotate the
housing.

10. Loosen the vise and reposition pinion housing assembly (2) in the vise as shown. Tighten the vise against the pinion housing so that the pinion
shaft is free to rotate.

11. Use tool (C) and a torque wrench to measure the torque needed to turn the pinion shaft. The torque must be 0.7 to 1.1 N·m (6 to 10 lb.in.) for
new bearings and .35 to .55 N·m (3 to 5 lb.in.) for used bearings.

12. If the torque required to rotate the pinion shaft is more than the torque specified in Step 11, loosen nut (6) 1/8 turn and tap the end of the pinion
shaft with a soft faced hammer to loosen the bearing preload. Repeat Steps 8 through 11 until the torque required to turn the pinion shaft is correct.

13. Use tooling (D) to check the end play of pinion shaft (3) as shown. After obtaining the correct torque required to turn the pinion shaft, there must
be zero end play of pinion shaft (3).

NOTE: If the collar (shoulder) of nut (6) is cracked during removal or restaking, the nut must be replaced.

14. Use tool (E) to stake nut (6) by peening the collar (shoulder) into the groove (slot) of the pinion shaft.

15. To obtain the best results during the peening operation, hold tool (E) at an angle of 10° to 30° from the face of nut (6), and peen an area 4.7
mm (.19 in.) long (minimum) and 2.5 mm (.10 in.) deep (minimum).

16. Fasten tooling (F) and a hoist to pinion housing assembly (2) as shown.

17. Do not install the O-ring seal around the pinion housing at this time.

18. Install the original thickness of shims (8) on the carrier housing, if the original gears, carrier assembly and housing are being used again. If any
of these parts are replaced, install 80% of the original thickness of shims.

NOTE: Shim pack (8) thickness may have to be changed when adjusting the tooth contact patter (backslash).

19. Put pinion housing assembly (2) in position on the carrier housing, and install the bolts that hold it. Tighten the bolts to a torque of 270 ± 25 N·m
(200 ± 18 lb.ft.).

20. Heat bearing cone (9) to a maximum temperature of 135°C (275°F), and install it on the differential case as shown.

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21. Put the bevel gear in position on wooden blocks as shown.

22. Put differential case (10) in position on bevel gear (12).

NOTE: New bolts (11) that hold differential case (10) to bevel gear (12) are coated with Loctite Dri-Loc 200. Install new bolts (11), and tighten them
to a torque of 135 ± 15 N·m (100 ± 11 lb.ft.). If the original bolts are reused, use the following procedure:

a. Use 6V1541 Quick Cure Primer to clean the threaded holes in bevel gear (12).

b. Put 9S3265 Retaining Compound in the threaded holes of bevel gear (12).

c. Install the original bolts that hold differential case (10) to bevel gear (12), and tighten them to a torque of 135 ± 15 N·m (100 ± 11 lb.ft.).

23. Turn the bevel gear and case assembly over as shown.

24. Put clean differential oil on washer (14), and put it in position in the case with the grooved face of the washer facing up toward gear (13).

25. Put gear (13) in position in the case as shown.

26. Put spider gears (15) and washers (16) in position on spider (17).

27. Put clean differential oil on spider gears (15), and install them and spider (17) in position in the case as shown.

28. Put gear (19) in position on the spider gears.

29. Put clean differential oil on washer (18), and put it in position on gear (19) with the grooved face of the washer facing down toward the gear as
shown.

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30. Put case (20) in position on case (10). Make sure the alignment marks on the cases are in alignment, and install the bolts that hold the cases
together. Tighten the bolts to a torque of 135 ± 20 N·m (100 ± 15 lb.ft.).

31. Heat bearing cone (21) to a maximum temperature of 135°C (275°F), and install it on the case.

32. Turn carrier assembly (24) with tooling (A) until the pinion housing is down as shown.

33. Put clean differential oil on bearings (9) and (21). Put bearing cones (22) in position on the bearings to protect them while installing the
differential assembly.

34. Put a bar or piece of pipe through the center of the differential assembly. Fasten a nylon strap and a hoist to the bar or pipe as shown.

35. Put the differential assembly in position in the carrier with the bevel gear on the side opposite pin hole (23) in the carrier.

36. Put bearing caps (25) and (27) in position on the carrier housing. Install the bearing cap bolts, only finger tight.

NOTE: Bearing adjuster nuts (28) must turn freely after they are installed.

37. Install bearing adjuster nuts (28) with the flat side of the nuts against the cage of the bearing cones.

38. Tighten one of the bolts (26) on each bearing cap (25) and (27) to a torque of 70 N·m (50 lb.ft.). Tighten the other bolt on each bearing cap to a
torque of 5 N·m (4 lb.ft.).

39. Use tool (G), and tighten both bearing adjuster nuts (28) and (29) evenly until there is a small amount of backlash and zero preload on the
differential bearings.

40. Turn the carrier assembly with tooling (A) until the pinion housing is in the horizontal position as shown.

41. Use tool (C) and a torque wrench to measure the torque required to turn the pinion shaft. Record this torque measurement.

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42. While turning bevel gear (30), use tool (G), and tighten the bearing adjuster nut on the side adjacent to the bevel gear until there is zero
backlash.

43. Loosen the bearing adjuster nut to the nearest position where the bearing adjuster nut lock can be installed (maximum of one lug movement).

44. Use tool (G), and tighten the bearing adjuster nut on the side opposite the bevel gear until the torque required to turn the pinion shaft increases
to 0.2 to 0.5 N·m (2 to 4 lb.in.) more than the torque measurement recorded in Step 41.

45. Put an alignment mark on bearing cap (25) adjacent to one of the lugs on bearing adjuster nut (27).

46. Put an alignment mark on bearing adjuster nut (27) three lugs counterclockwise from the mark on bearing cap (25).

47. Tighten bearing adjuster nut (27) until the two marks are in alignment. If the bearing adjuster nut lock cannot be installed, tighten adjuster nut
(27) until the lock can be installed.

48. Use tool (D), and measure the backlash between the bevel gear and pinion. The backlash must be 0.20 to 0.42 mm (.008 to .017 in.).

NOTE: The differential preload will be kept only if one bearing adjuster nut is loosened and the other adjuster nut is tightened the same amount.

49. If backlash is too much, loosen bearing adjuster nut (28), and tighten adjuster nut (29) the same amount.

50. If backlash is not enough, loosen bearing adjuster nut (29), and tighten adjuster nut (28) the same amount.

51. Tighten bolts (26) in bearing caps (25) and (27) to a torque of 475 ± 50 N·m (350 ± 37 lb.ft.).

52. After the gear clearance (backlash) and bearing preload adjustments have been made, check the tooth contact setting between the bevel gear
and pinion as follows:

a. Put a small amount of marking compound (Prussian blue) on the bevel gear teeth. Turn the pinion in both directions, and check the marks made
on the bevel gear teeth.

Correct Tooth Contact Setting

b. With no load, the correct tooth contact setting will be as shown. The correct area of tooth contact is located equally on both sides and starts near
the toe of the gear and goes 30% to 50% up the length of the tooth. With this setting, when a load is put on the gear, the load will be over the

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correct area of the teeth.

Short Toe Contact Setting

c. If the pinion shaft is too far away from the bevel gear, short toe contact will be the result as shown. The teeth of the pinion will be in contact with
the toe ends of the convex faces (part that makes a curve toward the outside), and the top edge of the heel end of the concave faces (part that
makes a curve toward the inside). To correct this, remove shims (8) from between the pinion housing and the carrier. After this is done, check the
gear clearance (backlash) and tooth contact again.

Short Heel Contact Setting

d. If the pinion shaft is too near to the center of the bevel gear, short heel contact will be the result as shown. The teeth of the pinion will be in
contact with the toe ends of the concave faces (part that makes a curve toward the inside) and the heel ends of the convex faces (part that makes
a curve toward the outside). To correct this, add shims (8) between the pinion housing and carrier. After this is done, check the gear clearance
(backlash) and tooth contact again.

NOTE: Several adjustments of both pinion and bevel gear may be needed before correct tooth contact and gear clearance (backlash) is made.
Always remember that a change to gear clearance (backlash) will also change the tooth contact. Therefore, be sure gear clearance (backlash) is in
correct adjustment before tooth contact is checked.

e. After gear clearance (backlash) and tooth contact are correct, remove the extra marking compound (Prussian blue) from the bevel gear and
pinion.

f. Install the O-ring seal between the pinion housing and carrier assembly. Again, tighten the bolts to a torque of 270 ± 25 N·m (200 ± 18 lb.ft.).

53. Install locks (31) and the bolts on each bearing cap.

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10/1/23, 9:01 SIS 2.0

54. Put 6V6640 Gasket Maker in the bore of retainer (32) before installing the lip-type seal.

en
55. Use tooling (H) to install the lip-type seal in the bore of retainer (32) with the lip of the seal facing up as shown.

56. Put the gasket and retainer (32) in position on pinion housing (2), and install the bolts that hold it.

END BY:

a. install front and rear differential

PSP-00072ED5
2023/01/10
14:00:56-05:00
SENR27690021
© 2023 Caterpillar Inc.
Caterpillar:
Confidential Green

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