Operation and maintenance manual

Front Axle Group - Differential Drive Head
8
Section 140-0060
SM 2148 5-02
6. Similarly, install second pair of clutch plates
followed by mating cage half (29).
Note: The clutch plates and cage half must be
assembled as the original matched set to ensure
correct operation of POWR LOK system. If unsure as
to which parts complete a set, measure total thickness
of clutch plates and cage half for both sides of
differential unit. Each total thickness figure must be
the same (See Fig. 8).
7. Install wheel (30) into cage half (29) engaging
splines with both friction plates (28) and end face hard
against thrust washer (26).
8. Assemble pinions (32) onto trunnion (31) and lay
assembly in place in cage half (29), in mesh with wheel
(30) as shown in Fig. 9.
9. Add remaining wheel (30) and cage half (29).
10. Stack alternate friction and steel clutch plates
(28 & 27) then check that cage half (29) and clutch
plates will slide in differential housing body (20) by
raising and lowering wheel (30).
11. If originally fitted, place shims on end face of
differential housing body (20). Install second thrust
washer (26) onto wheel (30) then carefully offer end
flange (53) to the assembly, lining up matching marks
(See Fig. 10).
12. Secure assembly with nuts (54) then tighten nuts
to a torque of 61 - 66 Nm (45 - 49 lbf ft).
13. To check assembly of differential unit, insert a
driveshaft to engage with each wheel (30). Hold one
driveshaft to lock wheel; the other must turn freely.
14. Press a bearing cone (24A) onto each end flange
(21 & 53) until hard against shoulder.
Initial Preparation Before Installing
Assembled Differential Unit
Note: Secure the crownwheel and gear casing
assembly in a suitable build stool.
Check fit of adjusting nuts (23) as follows:
1. Clean and deburr gear casing (17) legs and
straps (33).
2. Install bearing cups (24) into half bores of gear
casing (17) legs.
SM - 1208
3. Check studs (55), and replace as necessary.
Tighten to a torque of 129 - 142 Nm (95 - 105 lbf ft).
4. Carefully install two straps (33) and adjusting nuts
(23) to locate on bearing cups (24). Check the
Fig. 11 - Checking Freedom of Diff Bearing Adjusting Nut
SM - 1185
Fig. 10 - Differential Assembly