Operation and maintenance manual
Section 140-0060
5
SM 2148 5-02
bearing housing (63). Remove spacers (10 & 11) from
bevel pinion and retain for reuse if original pinion
bearings are to be reinstalled.
5. Remove inner bearing cone (12A) and nose bearing
(14) from pinion (13) if required.
6. Lift out outer bearing cone (64A) from bearing
housing (63). Bearing cups (64 & 12) can now be
drifted out of bearing housing (63) for replacement if
required.
Note: If either bearing cup or cone need replacing, they
must be replaced as a set.
Differential Shaft Disassembly
1. Straighten tab on lockplate (39). Remove left hand
threaded shaft nut (38), lockplate (39) and shaft
bearing (40) using suitable extraction equipment.
2. Pull off rear end cap (42).
3. Using suitable drift, remove and discard oil seal (41)
from rear end cap (42).
4. Remove all joint material from bearing recess in
rear end cap (42).
ASSEMBLY
Numbers in parentheses refer to Fig. 1.
Note: Prior to assembly, lightly oil bearings in clean
gear oil as specified in Section 300-0020,
LUBRICATION SYSTEM.
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
When necessary to drive on components
during assembly, be sure to use a soft drift to
prevent property damage and personal injury.
Bevel Pinion
1. If new nose bearing (14) is to be fitted, apply a light
coating of Loctite 641 to bore of nose bearing then
press onto pinion (13) hard against its abutment
shoulder. To retain bearing, lightly peen over end of
pinion shaft in three places as shown in Fig. 5.
Front Axle Group - Differential Drive Head
Note: Shims may have been fitted between end flange
(53) and differential housing body (20). These must be
replaced on assembly to maintain an operating
clearance within the differential assembly. The
components contained in the differential unit have been
carefully measured and selected to ensure correct
operation. DO NOT fit the components in a different
sequence to that of the original assembly or attempt to
change/introduce shimming. This will result in failure of
the POWR LOK system.
7. Remove first clutch plate (27) and friction plate (28)
followed by second pair of plates. Set aside plates so that
they can be reinstalled in their original position.
8. Slide out cage half (29) from differential housing
body (20).
9. From remaining cage half, lift out wheel (30),
pinions (32) and trunnions (31).
10. Remove second wheel (30) and cage half (29)
followed by two pairs of clutch plates (27 & 28) and
second thrust washer (26).
11. Unscrew and remove nuts (22) and bolts (18).
12. Separate end flange (21) from differential housing
body (20).
13. Using hide faced mallet, remove crownwheel (25)
from its register on differential housing body (20).
14. Inspect all parts of differential assembly. If there is
any wear or damage install new differential unit
complete. Renew crownwheel (25) and pinion (13) as
a matched pair.
Bevel Pinion Disassembly
1. Remove setscrews (65) then, using hide faced
mallet, knock out complete pinion assembly from gear
casing (17) taking care not to lose any of the pinion
setting shims (62).
Note: If the original pinion and crownwheel are to be
reinstalled, retain the shim pack as a unit for reuse.
2. Secure pinion assembly in a vice fitted with soft
jaws then remove end nut (67).
3. Pull off helical gear (66), using suitable extraction
equipment.
4. Tap pinion (13) along with spacers (10 & 11), inner
bearing cone (12A) and pinion nose bearing (14) out of