37R Hydraloc D&C Service Manual (Final)
Contents
1. 4 1 L Figure 66 Remove pinion shaft and retainer assembly from carrier Remove flange from pinion Remove pinion from bearing retainer Figure 67 Apply Loctite 515 or equivalent to outer diameter of pinion oil seal Using appropriate driver install seal with lip of seal facing in down 36R Hydraloc Differential Service Manual Figure 68 Install bearing retainer shims NOTE Install with reference hole in shims opposite ring gear Figure 69 Press pinion into bearing retainer assembly Install pinion and retainer assembly in carrier housing NOTE Line up oil holes in retainer and carrier housing Figure 70 Install 6 bearing retainer bolts and washers Tighten to 182 202 Nm 134 149 LBF FT Figure 71 Install flange and flange o ring Apply Loctite 270 or equivalent to threads and install flange nut Tighten to 600 800 Nm 443 590 LBF FT w Figure 72 Reinstall bearing caps cap bolts and washers Tighten to snug up Refer to Figures 63 amp 64 to set ring gear backlash bearing preload and recheck tooth contact pattern After optimum settings are made remove cap bolts and adjusting nuts one side at a time apply Loctite 242 or equivalent to bolt threads Loctite 222 or equivalent to adjusting nut threads reinstall and tighten bolts to 495 611 Nm 365 451 LBF FT NOTE Rechec2. Figure 39 Using appropriate driver install bearing cone on case cap half Position case cap half and bearing on clutch housing NOTE Be sure to match up alignment marks made during disassembly Figure 40 Install 16 case bolts and install with washers Tighten to 71 88 Nm 52 65 LBF FT zi 3 ae ae A rx s x e 3 lt ex fee Figure 41 Position clutch driver on splines of clutch side gear Figure 42 Install clutch driver to gear snap ring 36R Hydraloc Differential Service Manual Figure 43 Figure 46 Install 1 friction plate in clutch housing Install new inner and outer seal rings on piston NOTE Identify notch in splines Lubricate rings and piston bore in housing with grease Figure 44 Install 1 reaction plate Figure 47 Using soft faced hammer evenly tap piston into clutch housing NOTE Be careful not to damage seal rings Figure 45 Install friction plate aligning notch with previous friction plate Alternate reaction and friction plates until 6 of each are installed NOTES The notch in each friction plate must be aligned with the notch in the proceeding plate Be sure plates are lubricated with axle lubricant on both sides Figure 48 Align screw holes and match marks made at disassemb
3. Figure 56 Position bearing retainer on pinion Press outer bearing cone in place PINION BEARING SETTING PROCEDURE Figure 57 Install input flange and flange nut minimum 800 Nm 590 LBF FT dry thread Secure bearing retainer in vise to allow pinion to rotate Using an inch pound torque wrench check rolling resistance torque Rolling resistance should be 1 1 3 4 Nm 10 30 LBF IN If not within specifications add shim thickness to decrease torque or remove shim to increase torque IMPORTANT This rolling torque check must be made again with seal retainer assembly installed in the carrier housing Install seal retainer assembly in housing with original bearing cage shims and 4 retainer screws and washers Tighten screws to 182 202 Nm 134 149 LBF FT Repeat rolling resistance check Rolling resistance must be 1 1 3 4 Nm 10 30 LBF IN NOTE The flange will be removed after ring gear to pinion contact and backlash has been set Tighten nut to 25 36R Hydraloc Differential Service Manual Figure 58 Figure 61 Insert a bar as shown to facilitate lifting Position Position bearing caps on bearings and adjusting differential into carrier tilting it so that ring gear will nuts making sure match marks made during clear inner bearing bore boss in carrier disassembly are properly aligned Install 4 cap bolts and washers NOTE Tighten to snug up Do not
4. lt pana gt SPICER Off Highway Products service Manual 36R Hydraloc Differential Axle ASM 0159 september 2009 36R Hydraloc Differential Service Manual SO FOREWORD This manual has been prepared to provide the customer and maintenance personnel with Information and instructions on the maintenance and repair of Dana Products Extreme care has been exercised in the design and selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product it s principle of operation troubleshooting and adjustments it is urged that mechanics study the Instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana Important Always furnish serial and model numbers when ordering parts SAFETY PRECA
5. Freezing Guidelines 4 Cleaning and Inspection 6 Fastener Torque Chart 7 Plug and Elastic Stop Nut Torque Charts 8 Recommended Lubricants 9 Gear Tooth Contact Chart LH 10 Gear Tooth Contact Chart RH 11 Cross Section Illustration 12 Inner Pinion Bearing Staking 13 Pinion Depth Setting Procedure 14 Differential Assembly Exploded View 15 Differential Assembly Parts Description DISASSEMBLY 16 Differential Assembly Removal 16 Differential and Carrier Disassembly 19 Differential Disassembly REASSEMBLY 21 Differential Reassembly 25 Pinion Bearing Setting Procedure 27 Ring Gear and Pinion Backlash Setting Procedure 27 Ring Gear to Pinion Distance Setting Procedure 29 Differential Installation 36R Hydraloc Differential Service Manual lt BEARING HEATING AND FREEZING GUIDELINES Bearings often must be cooled or heated to aid in assembly or removal Since temperature extremes can cause permanent bearing metallurgical damage it is important to take proper precautions and use correct methods when heating and cooling bearings Cups that are to be assembled in hubs or housings with a press fit may be shrunk in a deep freeze unit Standard class bearings should not be cooled below 65 F 54 O In addition to cooling the bearing cup in some instances it may be necessary to heat the housing To control temperature is best to use a thermostat along with a freezer unit or a properly calibrated thermometer If a
6. previously recorded and this equals the amount of shims to be added between the inner pinion bearing cup and the carrier housing EXAMPLE 5 289 134 341 mm Value etched on ring gear 0 469 011 913 mm Constant 1 2 thickness of gauge bar 5 758 146 253 mm Total 5 728 145 491 mm Initial micrometer reading 0 030 762 mm Add this value in shims under inner pinion bearing cup 13 36R Hydraloc Differential Service Manual DIFFERENTIAL ASSEMBLY EXPLODED VIEW 14 36R Hydraloc Differential Service Manual ITEM OTY DE N UJ gt p a HH p BH NJ O B 0 HB PB pA N N N N FF F O a R H B HI mB FN H H H ONES DIFFERENTIAL ASSEMBLY PARTS DESCRIPTION RIPTION AXLE HOUSING VENT FILL PLUG PLUG O RING MAGNET DRAIN PLUG CARRIER AND CAP ASSY CARRIER CARRIER CAP CARRIER CAP WASHER CARRIER CAP BOLT DOWEL PIN LOCK WASHER BOLT O RING ADJ USTI NG NUT LOCK BOLT NUT LOCK TAPERED BEARING ADJ USTING NUT ROLLER BEARING CENTER PINION BEARING PINION SPACER O RING BEARING RETAINER SHIM BEARING RETAINER BEARING RETAINER BOLT BEARING RETAINER PLUG OUTER PINION BEARING OIL SEAL PINION NUT O RING PINION NUT CASE ASSEMBLY CASE BOLT CASE WASHER THRUST WASHER 15 ITEM OTY DE gt ZJ a OA OO FE FB PBB N Fa N OO FEP EF N a E Pr FEF RIPTION SIDE GEAR CLUTCH SIDE GEAR THRUST WASHER DIFFERENTIAL CROSS DIFFERENTIAL PINION GEA
7. solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners BEARI NGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning Bearings may be rotated slowly by hand to facilitate the drying process HOUSI NGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners Thoroughly dry all parts cleaned immediat
8. torque at this time Figure 59 Position differential bearing cups on each side over bearing cones Figure 62 Remove 2 temporally installed ring gear bolt nuts Install 10 ring gear mounting bolts Apply Loctite 242 or equivalent to bolt threads and install 12 nuts Hold pinion flange and tighten nuts to 182 202 Nm 134 149 LBF FT Figure 60 Install adjusting nuts on each side against bearing cup NOTE Turn adjusting nuts by hand to be sure of proper thread alignment 26 36R Hydraloc Differential Service Manual RING AND PINION BACKLASH SETTING B u Figure 63 Use a dial indicator as shown Move ring gear by loosening one adjusting nut and tightening opposite adjusting nut Adjust position until gear backlash is to backlash specifications of 0 23 0 33 mm 009 013 Use 0 33 mm 013 for new ring gear set or adjust to backlash recorded at disassembly for used gears Refer to Figure 3 When proper backlash is achieved tighten opposite adjusting nut to remove all end play on tapered bearings Using only thumb and forefinger move ring gear When ring gear becomes difficult to move preload on bearing is set Recheck backlash RING GEAR TO PINION MOUNTING DISTANCE SETTING PROCEDURE If mounting distance pinion setting gauge is used follow instruction supplied with gauge Refer to procedure on page 13 Use the followi
9. ES Pa Figure 8 Figure 11 Remove 2 adjusting nut lock bolts Match mark differential caps for reassembly Remove 4 cap bolts and washers Figure 9 Figure 12 Remove 2 adjusting nut locks Remove 2 differential caps 17 36R Hydraloc Differential Service Manual Figure 13 Remove 2 differential bearing adjusting nuts Figure 14 Remove 12 ring gear mounting bolt nuts Figure 15 Drive ring gear bolts through ring gear and remove 18 Figure 16 Remove differential assembly from carrier Remove bearing cones Figure 1 Remove 6 bearing retainer bolts and washers Figure 18 Remove pinion shaft and bearing retainer 36R Hydraloc Differential Service Manual Figure 19 Remove shims Press pinion from bearing retainer Figure 22 Remove bearing cups and oil seal from retainer Remove inner and outer piston seals DIFFERENTIAL DISASSEMBLY Figure 20 Figure 23 Mark flange half clutch housing and case half with alignment Remove ring gear marks for reassembly Remove case flange half x F Figure 24 Figure 21 Remove clutch driver snap ring Install a seal retainer and piston rings as shown Carefully and slowl
10. GS P N Size LBF FT Nm 5 16 24 24K 1 5 7 3 8 24 24K 2 8 11 7 16 20 24K 3 10 14 1 2 20 24K 4 13 18 9 16 18 24K 5 15 20 3 4 16 24K 6 25 34 7 8 14 24K 7 35 47 1 1 16 12 24K 8 50 68 1 3 16 12 24K 9 60 81 1 5 16 12 24K 10 75 102 1 5 8 12 24K 11 85 115 1 7 8 12 24K 12 85 115 PIPE PLUGS Size NPTF LBF FT Nm 1 16 27 7 9 1 8 27 10 14 1 4 18 20 27 3 8 18 30 41 1 2 14 35 47 3 4 14 45 61 1 11 1 2 55 75 1 1 4 11 1 2 65 88 ELASTIC STOP NUTS Size LBF FT Nm 1 20 200 270 1 1 4 18 250 340 1 1 2 18 350 475 1 3 4 12 450 610 36R Hydraloc Differential LAND Service Manual RECOMMENDED LUBRICANTS FOR DRIVE AXLES Recommendations Extreme pressure gear lubricant is recommended for use in all drive steer and rigid drive axles except where explicitly stated differently by Dana Off Highway Products Engineering Mineral Based Acceptable lubricants must meet API GL 5 MT or MIL PRF2105E qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below Limited slip designated GL 5 oil brands are preferred for quiet operating characteristics Universal Tractor Transmission Oils UTTO Fluids Acceptable lubricants must meet Dana MS266 or J Deere J20C specifications Use the highest viscosity grade for the ambient temperatures from the temperature chart below Synthetics Synthetic lubricants are r
11. N GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 10 Service Manual CROSS SECTION 36 dral iff ial bear E INNER PINION BEARI NG STAKI NG When the inner pinion bearing or the pinion shaft and ring gear are being replaced staking of the pinion end to the inner pinion bearing is required If a staking groove is in the pinion shaft use procedure shown in Figure A and a square end staking tool as shown If pinion has no staking groove use procedure in Figure B and a standard prick punch to upset the metal over the bearing inner race FIGURE A NO STAKING GROOVE FIGURE B 12 36R Hydraloc Differential Service Manual PINION DEPTH SETTING PROCEDURE The function of the pinion setting gauge is to measure the distance from the centerline of the differential bearing bores to the ground surface on the gear end of the pinion This measurement when subtracted from the value etched on the ring gear will Indicate the size of the shim pack required to position the pinion gear in proper relation to the ring gear On the outer diameter of the ring gear a ring gear to pinion distance will be etched add 4649 11 808 mm to it 4649 11 808 mm is half the th
12. R THRUST WASHER DIFFERENTIAL CASE SEAL RING amp PINION SET RING GEAR MOUNTING BOLT CASE FLANGE HALF PLUG NUT CLUTCH PISTON OUTER SEALING RING INNER SEALING RING SEAL RETAINER OIL PASSAGE PLUG PISTON RING BALANCE PISTON O RING NIPPLE PRESSURE PORT O RING FILTER PLUG NIPPLE TANK PORT O RING EXTENSION TUBE SEALING RING CLUTCH DRIVER SNAP RING INNER DISC OUTERDISC PINION FLANGE PINION BEARING SHIM 36R Hydraloc Differential Service Manual DIFFERENTIAL ASSEMBLY REMOVAL DISASSEMBLY A yr Figure 1 Figure 4 Remove differential to axle bolts and washers Loosen flange nut Figure 2 Install 4 pusher bolts in the threaded holes in the carrier flange Attach lifting device to input flange Figure 5 Remove flange nut Remove flange nut o ring Figure 3 Tighten 4 pusher bolts evenly and lift differential assembly straight up and off of dowel pin Mount differential on suitable overhaul stand Figure 6 I MPORTANT Using a dial indicator check and record ring Remove flange gear backlash at this time This information is necessary for reassembly unless a new gear set is installed 16 36R Hydraloc Differential Service Manual Figure 7 Figure 10 Remove tank and pressure port nipples Remove seal retainer Remove 2 seal rings w 4 NT T wi aT pem d L
13. ULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION FIG 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIOLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 36R Hydraloc Differential Service Manual RIGHT HAND SPIRAL SPIRAL BEVEL AND HYPOID TOOTH BEARING CHART unis TOWARD THIS DIRECTION MONE GEAR AWAY FROM GEAR T PINION IN THIS DIRECTION PINION IN ET END ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER A LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RESULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION FIG 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING O
14. UTIONS To reduce the chance of personal injury and or property damaged the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part Do not use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of purpose designed tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither his safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may damage the unit or render it unsafe It is important to understand that these Cautions and Notices are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions 36R Hydraloc Differential Service Manual TABLE OF CONTENTS 1 Forward and Caution 2 Table of Contents 3 Bearing Heating and
15. ecommended providing they meet API GL 5 MT 1 qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases This produces a thickening of the mineral oil at the contact point This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and spalling fatigue Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so Before using a synthetic lubricant in heavy applications the customer must check with the lubricant supplier on the issue of high pressure lubricant applications Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Extended Oil Change Interval Extended oil service may result when using synthetic lubricants Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a base line Wear metal analys
16. ely by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound I NSPECTI ON The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARI NGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAI NI NG RINGS Replacement of spring loaded oil seals gaskets and snap rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing member should be handled carefully particularly when being installed Cutting scratching or curling under lip of seal seriously impairs its efficiency At reassembly lubricate lips of oil seals with Multipurpose Lithium grease Grade 2 36R Hydraloc Differential Service Manual P eere CLEANI AND INSPECTI ON CONT GEARS AND SHAFTS If Magna Flux or a dye penet
17. ickness of the gauge bar Record this value This value may be different on each ring and pinion set due to manufacturing variations Use a file and emery cloth to remove all burrs and nicks from machined bearing surfaces of carrier housing Paint bearing surfaces with bearing contact checking compound Insert an extension depth micrometer Starrett 44B 6RC and extension 99347 7 178 mm or equivalent is recommended into the guide bore of the micrometer arbor and slide clamps over base of micrometer With the thumb screws reacting on base secure micrometer IMPORTANT The micrometer extension must pass freely through the micrometer bar guide bore and base of the micrometer must rest on the micrometer arbor when mounted Mount adapter discs on micrometer arbor and set in position in carrier housing Exercise care to be sure that micrometer and extension do not contact any part of the carrier in this operation Apply pressure by hand and rotate adapter discs slightly to obtain a contact with bearing surfaces Remove checking gauge assembly and check for full bearing contact on bearing surfaces If contact is full and proper again position checking gauge assembly in carrier and check distance to ground surface on pinion Do not apply pressure to arbor or micrometer Turn micrometer carefully and evenly until the flat tip of the micrometer extension contacts the ground surface of the pinion squarely Subtract this reading from the value
18. is can provide useful information but an axle should not be removed from service based solely on this analysis Vehicles which are prone to high levels of ingested water in the axle or water as a result of condensation should not use extended drain intervals Friction Modifiers Friction modifiers may be used with the lubricant to reduce Posi Torq limited slip differential noise or liquid cooled brake noise If friction modifiers are used follow instructions on TSB 278E The use of aftermarket lubricant additives other than those specified is not recommended and may reduce the life of the axle and void the warranty Viscosity Based on Prevailing Ambient Temperature 80W90 75W90 40 30 20 10 O 10 20 30 40 50 40 4 14 32 50 68 86 104 122 36R Hydraloc Differential Service Manual LEFT HAND SPIRAL SPIRAL BEVEL AND HYPOID TOOTH BEARING CHART NTER MOVE PINION TOWARO K roe GEAR IN THIS OIRECTION MOVE PINION AWAY FROM ADDENDUM PROFILE EU DEDENDUM PINION IN THIS DIRECTION PINION IN THIS OMEGO AN gi ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER A LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RES
19. k for proper ring gear backlash and bearing adjustment after final torquing 28 36R Hydraloc Differential Service Manual DIFFERENTIAL INSTALLATION Figure 73 Install 2 piston rings on carrier journal Lubricate rings and seal retainer with grease Install seal retainer Figure 76 Install new carrier to axle housing o ring on carrier Install alignment dowel pin in axle housing mma d Figure 74 Figure 77 Apply Loctite 242 or equivalent to bearing Apply light coat of grease to pilot on flange of carrier nut lock bolt and install with nut lock Lower assembly carefully into axle housing Align Tighten to 16 26 Nm 22 19 LBF FT dowel pin with hole in carrier Tap lightly at dowel pin Repeat with bolt and nut lock on opposite side location while lowering assembly into position Figure 75 Install new square cut seals and o rings to nipples Install nipples in carrier housing and tighten to 40 50 Nm 29 37 LBF FT 29 36R Hydraloc Differential Service Manual Figure 78 Install 24 carrier to axle housing bolts and washers Figure 79 Tighten 24 bolts to 182 202 Nm 134 149 LBF FT 30
20. ly on flange half case with clutch housing 23 36R Hydraloc Differential Service Manual Figure 49 Install case flange half Using appropriate driver install bearing cone on flange half case Figure 50 Turn differential body assembly over Heat ring gear to 93 100 C 200 212 F and install using 2 ring gear bolts located 180 apart in ring gear to aid in alignment of bolt holes CAUTION Use gloves to avoid injury Temporaraly install 2 nuts and tighten to 135 Nm 100 LBF FT 24 Kua UE j aj T T Ir k a E MIL U X P a Bn SE en 2 a Ee ii 4 oe Figure 51 Press inner bearing on pinion Figure 52 Stake pinion to bearing inner race n 4 places equally spaced around diameter Refer to instructions on page 12 Figure 53 Press center bearing on pinion shaft with the large diameter of bearing towards gear teeth 36R Hydraloc Differential Service Manual 4 LE Figure 54 If the ring and pinion tapered bearings or bearing retainer were not replaced install the original bearing spacer and shim If new parts are used a shim kit should be used Install the spacer provided in the kit along with same thickness shim removed plus an additional shim Figure 55 Install center and outer bearing cups in bearing retainer
21. ng procedure when the pinion setting gauge is not used Check ring and pinion gear for proper tooth contact Paint ring gear with a gear tooth marking compound When ring and pinion gears are rotated the compound is squeezed away by the contact of the teeth leaving bare areas the exact size shape and location of the contacts As a rule painting about 10 or 12 teeth is sufficient for checking purposes Sharper impressions may be obtained by applying a small amount of resistance to the ring gear with a flat steel bar and using a wrench to rotate the pinion Gears should be rotated under slight load until ring gear has turned at least one revolution in both directions Check tooth contact pattern on drive side convex side of ring gear teeth Coast side will automatically correct when drive side pattern is correct Refer to gear tooth contact charts on pages 9410 If proper tooth contact pattern is not as shown readjust backlash or add to or subtract from shim pack between bearing cage flange and differential housing Addition of or subtraction of shims should be made in small increments until proper contact is established After optimum tooth contact is made the differential and pinion must be removed from the carrier this will allow for proper sealing measures at reassembly Figure 64 27 Figure 65 Remove differential assembly from carrier Refer to Figures 11 13 v 1 WNO 7
22. rant process is available use process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines HOUSI NGS COVERS AND CAPS Inspect housings and covers to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures 36R Hydraloc Differential Service Manual FASTENER TORQUE CHART STANDARD FASTENERS Lubricated and Plated Bolts CapScrews and Studs Grade 5 Grade 8 3 Radial Dashes On Bolt Head 6 Radial Dashes On Bolt Head LBF FT Nm LBF FT Nm 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 METRIC FASTENERS Lubricated and Plated Bolts CapScrews and Studs Class 8 8 Class 10 9 Class 12 9 8 8 on Bolt Head 10 9 on Bolt Head 12 9 on Bolt Head LBF FT Nm LBF FT Nm LBF FT Nm 36R Hydraloc Differential Service Manual PLUG amp ELASTIC STOP NUT TORQUE CHARTS O RI NG PLU
23. suitable freezer or thermometer is not available your Timken service representative can suggest liquid combinations that freeze the bearing cup at the optimal temperatures Regardless of the method check the cup s final seating against the housing shoulder with feeler gauges Take extreme care that standard product bearings are never heated above 149 C 300 F If bearings are heated above this temperature their metallurgical structure may soften rendering them unsuitable for use There are a number of recommended methods for heating bearings Electric ovens or electrically heated oil baths may be used but only when accompanied by proper thermostatic control If you use a hot plate to heat the oil never rest bearings directly on the bottom of the pan Instead protect bearings from the heat source with a simple wire screen holder or similar device Use heat resistant gloves to handle heated cones Hold the hot cone solid against the cold shoulder on the shaft until the cone grabs on to the shaft The hot cone will pull away from the cold shoulder unless it is held in position Use 002 05 mm feeler gages to make sure the cone is fully seated against the shoulder after the parts are cooled Many loose bearing settings excessive end play are caused by an unseated cone working back against the shoulder in service 36R Hydraloc Differential LAND Service Manual CLEANING AND INSPECTI ON CLEANI NG Clean all parts thoroughly using
24. y apply compressed air to port in distributor to remove piston Using appropriate puller remove bearing cone if replacement is required 19 36R Hydraloc Differential Service Manual Figure 25 Figure 28 Remove friction and reaction plates Remove 16 case cap half to clutch housing bolts and washers Figure 26 Figure 29 Remove clutch driver Separate case halves Figure 27 Remove differential case seal Figure 30 Using appropriate puller remove bearing cone if Remove side gear and thrust washer replacement is required from case cap half 20 36R Hydraloc Differential Service Manual DIFFERENTIAL REASSEMBLY NOTE All parts must be lubricated with axle lubricant at reassembly No part should assembled dry 4 Figure 31 Remove differential cross pinions and thrust washers from clutch housing Figure 34 Position side gear thrust washer clutch housing Figure 32 Remove clutch side gear Figure 35 Install clutch side gear Figure 33 Remove clutch side gear thrust washer Figure 36 Assemble differential cross 4 pinions and 4 thrust washers and install as an assembly 21 36R Hydraloc Differential Service Manual Figure 37 Position standard side gear on pinion and cross assembly Figure 38 Place side gear thrust washer on side gear
Download Pdf Manuals
Related Search