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t/lAINTENANCE MANUAL
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GENERAL INFORMATION
General Precautions for Assembly and Disassembly . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
........
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
Lubricant Change Schedule ..
Torque Specifications.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
Axle Identification . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
... .. ..... ... . . 3
Gear Set Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
CARRIER SECTION
Carrier Assembly (Illustration) . . . . . . . .. . . . . . .
. . .. ... ... .. . .... ... . . . .. ...... . . .. ........ .. 5
Removal of Carrier from Axle Housing . . . . . . . .
.. ... ..
.. .... .. ... . . 6
Removal of Differential from Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Differential Disassembly . . .
. . .. . . .. . ..... . . .. . . . . . ... . . ... . . . . . . . . . . .... ....... ... .. 7
Pinion Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8, 9
. .. . .. . . ... .. . .... ... .... , .. . ... . . . . . . .. . . . . ..... . .. . . ..
10,11 ,12
Pinion Assembly ..... .
Pinion Posi tion ....
.... . . . . ... .. ... . .. ..... .. ... .. . . ..... ... .. . . ..... . ...... ... . . ..
. ... .. 13, 14,15
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .... . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . .. ... .. .
. . . .. 16
Differential Installation . . . . . . . .
. . . .. ... . .
. . . . . . . . . . . . . .. . . ... . . . . . . . . . . . . . . . . . .. . . . . .. . . 17
Ring Gear and Pinion Tooth Contact Pattern ..... ... .... . ......... . . ... .. .. . .. . .. ..... . . . . .... . .... .. . . . .. . 18, 19
1~::~:Lo:~:;pe~:~s;mbIY into Axle Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
Pinion Mount WelDisc Brake Di sassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . ... 21 , 22
Pinion Mount Wet Disc Brake Assembly .. . . . . . . . . . . . . . .
.. ...... .
. . . . . . . . .. .
. ......... . 23, 24
NoSPIN Differential Disassembly. . . .
. . . . . . . .
. .. ... . ... ... .. . .. . . ... .. ...... .... ... ... . . . 25, 26
NoSPIN Differential Assembly ........................ .... .... .. .. , ..... ... . ..... . . . .. . .... .. . , ..... .... 27, 28
Installation Test(NoSPIN Differential) .... .. .. . .... .. ... ... .. . ... c. . ~ . . . . .... . . .. . . .. .. . . . . . . . . . .... . . ....... 29
Trouble Shooting (NoSPtN Differential) . . . . . . . . . . . . . . . . . . . .. .. .. . . .. . . . . . . .. . . . . . .. .. . . . . .. . . . . . .. 30
. .... ... . ... .. .... .. ..... .. 31
Differential Lock (Illustration) . . .
. . . . ... .
Differential Lock Disassembly . . . . . . .
. . . .. . . . . .. . . . . . .. .. . . . . . . . . . . . . .. .. . . . . . . . .. . . .. 3133
Differential Lock Assembly. . . . . .
. ....... ... . . ..... . ........ .. .. .... .. . . ... . ....... .. . ..... 3437
38,39
Inspection arid Failure An alysis .. .. " . .. . .... ... ... . ... . ......... .. .... . . . .. . . . . ... .. .... . . .. . ... . .. ..
Diagnosis of Rear Axle Problems . .... . .. . . .. .. .. . .. . . ........... . . . , . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40
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CONTENTS
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Models PS/PR-1350
Carrier Assembly, Pinion Mount Wet Disc Brakes,
NoSPIN Differential Option, Differential Lock Option
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rts supplier. The use of non-original equipment replacement parts is not recommended as their use may cause unit failure
and affect vehicle safety.
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Pinion Disassembly
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12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
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1. Remove pinion cage cap screws which hold pinion
assembly to the carrier housing.
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Pinion Assembly
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10. Inspect end yoke or flange seal surface for grooves
caused by lip of seal. If grooves can be detected with
fingernail , it should be replaced .
11. Install end yoke onto pinion, without seal, and
torque to 325 ft. lbs. (400 NM) so bearing preload can
be checlied.
NOTE: Pinion cage should be rotated while
tightening pinion end nullo seat and align the
pinion bearings.
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lilt
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lilt
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M.M.
13.04
13.12
13.19
13.27
13.32
13.35
13.37
13.40
13.42
13.45
13.47
INCHES
.5315
.5325
.5335
.5345
.5355
.5375
.5395
.5405
.5435
.5485
M.M.
13.50
13.52
13.55
13.58
13.60
13.65
13.70
13.73
13.80
13.93
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LENGTHWISE
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shown above.
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6. If pattern is concentrated at the tooth top land (as
shown above), the pinion is too far away from the ring
gear and must be moved closer to the ring gear to
establish its proper mounting distance and tooth
contact pattern. This is accomplished by selecting a
thinner pinion bearing cage shim. Readjust
pinion-to-ring gear backlash as required once proper
mounting distance has been established.
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11
9
B. Sialionary Disc
9. Rotating Disc
to. Piston
11. O-Ring
12. O-Ring
13. Oil Seal
14. Power Plate
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maintenance manual.
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Description
The NoSPIN differenlial provides equal amounts of
drive tin e torque to both right and len driving wheels
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4 Spring Retainer
5 Side Gear
Differential Removal
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,
1 Spider Assembly
2 Clutch Member Assembly
3 Spring
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- - _ ._ - _ .. _ --
- - -- - -- - - -
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: ttnstallation Test
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LEFT WHEEL
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Step 4
reversed.
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Step 3
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Step 5
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Operation Test
Check to see that both wheels of each NoSPIN
differential equipped axle are driving , Make this test
under load, so that engine torque is applied through the
NoSPIN differential with the wheels on the ground,
One way to achieve this load is to drive up against a
solid obstruction (on loose dirt or gravel, if possible)
and attempt to spin both wheels together. 'Perform this
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'NOTE: NoSPlN difle'erma" ..... Memil occasional "melal(.c;" 5OU1'Ids d\l9lO backlash bu~1
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clutch assemblies
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PROBLEM
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1. Indicator Switch
2. Screw (Guide)
3. Jam Nut
4. Spring Retainer
5. Spring
6. Rod
7. Fork
8. Bushing
9. Hex Bolt
1O. Flat Washer
t 1. Piston
12. Oil Seal
t 3. Shaft (Pivot)
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13. Inspect bronze pivot bushings in fOrk. If worn.
replace.
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indicator switch.
24: Actuate differenliallock from cab of vehicle and
verify engagemen t with indicator light.
25. Install steering cylinde r.
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looth loe.
RECOMMENDED REPAIR
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PROBABLE CAUSE
1. InsuHicient lubrication
2. Contaminated lubricant.
FAILURE MODE
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This section is intended to serve as a gUide for describing and explaining commonly encountered axle problems or
failures, and for recommending appropriate repair procedures.
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4. Contaminated lubricant.
2. Insufficient lubrication .
1. Vehicle overloading.
2. Vehicle accident.
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3. Shock loading.
1. Insuflicientlubrication.
2. Conlamina\ed lubrtcant.
3. Very severe service.
4. Normal wear.
38
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) .. ,etnspection and Failure Analysis
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3. Pinion endplay.
1. Severe servica.
3. Inadequate lubrication.
4. Contaminated lubricant.
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1. Insufficientlubricalion.
2. Improper lubrication.
3. Contaminated lubricant.
Severe service.
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Severe service.
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1. Severe service.
2. Loose pinion nul.
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looseness.
RECOMMENDED REPAIR
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PROBABLE CAUSE
FAILURE MODE
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Noise on Drive
Noise on Coast
RECOMMENDED REPAIR
1. Adjust
2. Replace
3. Replace
4. Adjust
5. Adjus t
6. Replace
7. Adjust
8. Replace
9. Replenish
10. Replace
11. Replace
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PROBABLE CAUSE
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1. Adjust or replace
(See above)
2. Adjust
IntermIttent
Noise
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Constant Noise
1. Replace
2. Tighten
1. Replace
2.
3.
4.
5.
6.
Replace
Replace
Replace
Replace
Replace
1. Replace
2. Replace
3. Replace
4. Replace
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Noisy on Turns
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