Carrier Assembly Reconditioning

Tool No. 999 2529, Floor Stand And 999 2522, Fixture:

DISASSEMBLY
1. Mount rear axle in fixture 2522. Use floor stand 2520 or bench stand 5154.
2. Remove inspection cover.





3. Check backlash. Use plate 5971 for magnetic stand, together with dial gauge. Note reading.





4. Remove drive (axle) shaft pressure plates and drive (axle) shafts (use brake disc).





5. Remove [1][2]differential from rear axle Remove bearing caps.
- Mount expansion tool 2394 and holder 2601. Expand tool until it engages holes and continue to turn through a maximum of 2.5 turns until [1][2]differential can be lifted out. Remove tool.
- Note location of bearing races to ensure that these are reinstalled in the same position.





6. Remove differential bearings and locking plate with puller 2483. Note bearing locations to ensure that bearings are reinstalled in the same position.

NOTE: On type 1041 rear axle, retain shims. Same shims must be reinstalled on same side when reassembling.





7. Remove crown wheel from [1][2]differential. Use counterhold 5425. Mount counterhold in vice and mount differential on counterhold.

NOTE: Differential lock must be replaced as a unit if [1][2]differential housing or housing end plate are damaged.





8. Slacken three bolts securing [1][2]differential housing to flange.
- Tap bolt heads lightly to separate end plate from housing.
- Turn housing upside down and remove bolts. Lift off end plate. [1][2]Differential gear adjusting washer may remain attached to plate.





9. Lift out [1][2]differential gear on crown wheel side, complete with plate assembly, guides and adjusting washer (if not already removed with end plate).
10. Remove engagement/disengagement mechanism.





11. Remove pinion shaft ([1][2]differential gear) locking pin.
Use a 4 mm (3/16 inch) cylindrical drift approximately 65 mm (2.5 inch) in length.
Place [1][2]differential housing on counter hold 2861 with of of the recesses opposite locking pin hole.





12. Remove pinion shaft ([1][2]differential gear). Tap out shaft from opposite locking pin hole.





13. Remove the reaction block and [1][2]differential gear set and pressure plates.

NOTE: If gear set is not to be replaced, mark gears to ensure they are installed in correct positions when reassembling.





14. Remove locking ring securing plate assembly on crown wheel side
15. Remove plate assembly, guides and cam wheel from [1][2]differential gear





INSPECTION
- Wash all components.
- Inspect for wear, cracking and other damage.

ASSEMBLY

NOTE: Oil all components with final drive oil prior to assembly





16. Install plate assembly on inner [1][2]differential gear. Use grease to hold guides in position on plate assembly.
A = Adjusting washer (in illustration).





17. Install [1][2]differential gear and plate assembly in housing.
Before installing [1][2]differential gear and plate assembly, place new adjusting washer of same thickness as original in housing.





18. Install:
- differential pinions (observe markings) and thrust washers
- reaction block
- pinion shaft ([1][2]differential gear)

Tool No. 999 5912, Drift:

19. Mount a C-clamp in a vice.
Center reaction block between the differential pinions.
Use C-clamp to clamp [1][2]differential housing between reaction block and differential gear bearing seat.
Use drift 5912 between clamp and reaction block.





20. Mount a magnetic stand and dial gauge on [1][2]differential housing face. Measure the backlash between differential gear and pinion at inner side of housing.
Measure backlash of both differential pinions. correct value is 0.025-0.15 mm (0.009800.0591 inch). Shims of different thickness are available if clearance requires adjustment.
Place dial gauge plunger in middle of tooth. Press pinion in direction of thrust washer while measuring clearance. If adjusting, repeat steps 12 and 13 and steps 16-20. Recheck clearance.





21. Tap out pinion shaft (in correct direction)
22. Remove reaction block and differential pinions and thrust washers. Note: Marking on each side.
Remove [1][2]differential gear and plate assembly and shim





23. Install:
- differential pinions. Ensure that each pinion is located on correct side after measurement.
- thrust washers
- reaction block
- pinion shaft (in correct direction as indicated by arrow). Tap shaft into housing until it engages hole at other end. Use brass drift.
24. Place [1][2]differential gear on crown wheel side in engagement with pinions in differential housing
Install new shim of same thickness as original at end of differential gear. Apply a little grease to hold shim in position.





25. Install:
- [1][2]differential housing end plate
- housing joint bolts (three)
Tighten bolts to 10 Nm (6-8 ft. lbs.).

Tool No. 999 5056, Drift:

26. Mount [1][2]differential housing as before in C-clamp.
- Place drift 5912 against reaction block.
- Place drift 5065 between drift 5912 and C-clamp.
27. Centre reaction block and tighten C-clamp

Measurement Of Backlash Between Differential Pinions And [1][2]Differential Gear On Crown Wheel (Ring Gear) Side.





28. Mount plate 5971 in position using one of crown wheel bolt holes
29. Mount magnetic stand and dial gauge in position
30. Measure backlash of [1][2]differential gears
Correct clearance should be 0.25-0.43 mm (0.0984-0.1693 inch). Shims of various thicknesses are available if clearance requires adjustment.
Repeat step 8 and steps 24-30, and recheck clearance.





31. Remove:
- magnetic stand
- plate 5971
- bolts (three) in end plate
- end plate
- [1][2]differential gear on crown wheel side
- shim
- pinion shaft (Note: Tap out in correct direction)
- differential pinions
- thrust washers
- reaction block





32. Tighten:
- [1][2]differential gear at inner end of differential housing complete with correct shim and plate assembly
- [1][2]differential gear at crown wheel end with correct shim in end plate
Modify two large M12 flat washers as illustrated.
When tightening, use two M12 bolts, two large flat washers, nuts and modified washers. Place washers against [1][2]differential gears.





33. Assemble [1][2]differential housing and housing end plate
Tighten three bolts to 8-10 Nm (6-8 ft. lbs.).





34. Measure clearance between axial faces of [1][2]differential gears
Use calliper for internal measurement and note reading.





35. Measure thickness of reaction block
Use micrometer and note reading.
Clearance between [1][2]differential gears and reaction block should be 0.10-0.24 mm (0.0039-0.0945 inch).
Reaction blocks are available in different widths. Select block which gives correct clearance.





36. Remove the [1][2]differential housing end plate. Also, remove bolts, complete with washers and nuts, securing differential gears.





37. Ensure that [1][2]differential gear, together with plate assembly, guides and shim, are correctly seated in differential housing.





38. Install:
- differential pinions (gear shafts) as per markings
- thrust washers
- reaction block (with flat face towards large opening in housing, as illustrated)
- pinion shaft (positioned as illustrated)
Align locking pin hole in shaft with hole in [1][2]differential housing as illustrated in step 39 below. Use 4.5 mm (3/16 inch) drill bit.
Tap in shaft carefully. Use drill bit inserted in flat face of [1][2]differential housing to check that holes are aligned with each other.





39. Install new locking pin
Tap in pin from flat face of [1][2]differential housing. Ensure that pin (arrow in illustration) is seated approx. 0.5 mm (0.0197 inch) below face.





40. Install weighted latch and centrifugal weights
Ensure that latch spring is positioned on correct side of governor weight axle.





41. Install toothed cam wheel and weight assembly on [1][2]differential gear at crown wheel (ring gear) end. Use grease to hold guides in position.





42. Install [1][2]differential gear at crown wheel end in differential housing, complete with plate assembly and guides
Use grease to hold shim at end of gear in position.
43. Ensure that mating surfaces of [1][2]differential housing and housing end plate are decreased. Use methylated (mineral) spirits or similar agent.





44. Install [1][2]differential housing end plate
Tighten three bolts to 8-10 Nm (6-8 ft. lbs.).





Toothed Wheel (Speed Sensor) Replacement
45. Remove toothed wheel Use snips to cut off wheel as illustrated.

Tool No. 999 2861, Counterhold:

46. Install new wheel
Oil wheel and seating surface on [1][2]differential housing. Tap on wheel lightly with rubber mallet. Ensure that wheel is straight.
Place [1][2]differential housing on counterhold 2861 as illustrated and press on wheel until housing meets tool.
47. Ensure that mating surfaces of [1][2]differential housing and housing end plate are decreased. Use methylated (mineral) spirits or similar agent.





48. Install crown wheel.
Use counterhold 5425. Mount counterhold in vice and place [1][2]differential on counterhold. Use new bolts. Tighten alternately to 35 Nm (26 ft. lbs.) and angle-tighten through 60 degrees. Use protractor 5093.
- First insert two bolts in small holes in [1][2]differential housing.

NOTE: On type 1041 rear axle, if differential lock has been replaced, new bearing is to be installed or backlash clearance is outside specifications, proceed to: Ring and Pinion or Bearing Replacement Ring and Pinion or Bearing Replacement. If none of these conditions applies, proceed to step below.





49. Install locking plate A and differential bearings with associated shim (model 1041 only)
Use drift 4112 as support at each end.