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International Harvester CTS-11/12 R

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1. a a Electric shift motor Spring completes shift when engine torque is released Shifting I Aic e t as atarata 00 OU S Il m 2 Zn JM 4 ra Seal Rear axle housing Bracket e Shims for adjusting moyement of shifting fork A 22922 Fig 6 Showing details of side mounted elect ric shift mechanism Shims are provided to ad just travel of shift fork Overhaul procedure for the electric shifting unit is given in the Electric Shift Section H Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section E Page 4 Fig 7 Adjusting stop screws to limit travel of shifting fork Fig Y shows point of contact of the screws with the shifting collar Adjusting screws located on top of the car rier housing Fig 7 provide means of limiting the travel of the shifting fork and rail Turn in or outon eachadjusting screw to stop the travel of the shifting fork so that the fork does not bear against the sides of the shifting collar after the collar is seated flush with the spur pinion face inboth high and low positions There must be a minimum of 010 clearance between the fork and shift collar This clearance is to assure that the collar is free of shifting fork interference and allows the poppets to hold the collar against either of the spur pinions Also the 010 minimum clearance is running clear ance between the forks and collar sides to pre vent unnecessary wear to th
2. 1934 YUVaIAY 1 TXV CODE 1425 1426 1428 1429 1430 1433 1435 1436 1438 1450 1451 1452 1453 1454 1455 1456 1457 1458 1459 Donated by John amp Susan Hansen For Personal Use Only REAR AXLE APPLICATION AND LUBRICATION CAPACITIES Continued R LINE TRUCKS HYD ENGINEERING NUMBER DESCRIPTION TRUCK MODELS CAPACITY IH Two Speed With IH Two Speed With RF 1475 E 22M MS IH Single Reduction RF 170 11 ea axle RF 1575 BEEN E 22M MEME Eaton Single Reduction RF 174 190 14 ea axle RF 1685 EE E 36M cmNEN Eaton Single Reduction RF 194 210 d da R 2795 R 2796 TR 300 TR 300 Timken Two Speed R 200 34 20 Forward RF 1690 NES Eaton Single Reduction RF 194 210 21 Rear R 1470 m IH Single Reduction R 164 170 173 175 8 UFACTURER S NUMBER R 2610 E 13600 Eaton Two Speed R 164 170 173 175 11 RF 1570 MS E 28M Eaton Single Reduction RF 174 190 14 ea axle R 2575 R 2576 E 17500 E 17501 R 184 190 193 195 17 R 2620 R 2621 E 18500 E 18501 Eaton Two Speed R 194 200 205 16 R 2366 ae E 1350 BEEN Eaton Two Speed R 150 153 13 R 1572 R 1573 E 1790 Eaton Single Reduction R 184 190 193 195 22 R 1632 R 1633 E 1890 E 1891 Eaton Single Reduction R 194 200 205 21 Zz aed suotneotrjt2edg UVIY SITXV AOIAMAS AONUL YOLOW ANITY NS Donated by John amp Susan Hansen For Personal Use Only AXLE REAR L LINE MOTOR TRUCK SERVICE MANUAL e age RE
3. 11 S L2 10 sadud e3u2u3 ddng 61 HOUVYW ZI S LO VOISBAWY JO 534vV1S O2LINN NI Q34NIBd Donated by John amp Susan Hansen For Personal Use Only REAR AXLE APPLICATION AND LUBRICATION CAPACITIES R LINE TRUCES IH MODEL MANUFACTURER S PUB CODE ENGINEERING NUMBER NUMBER DESCRIPTION TRUCK MODELS CAPACITY 1401 R 1060 Single Reduction R 110 4 1402 R 1070 Single Reduction R 120 RM 120 RA 120 4 1403 R 1170 Single Reduction 1404 R 1440 1405 R 1470 Single Reduction R 164 170 173 175 8 R 174 Hydraulic R 180 1406 R 1530 R 1531 Single Reduction R 183 185 1853 RC 180 a 1409 R 1740 R 1741 T R 100 T R 100 Single Reduction R 194 200 201 202 205 36 1410 R 2464 ae E 13600 Eaton Two Speed R 160 163 165 RC 160 13 1411 R 2467 ae E 13600 Eaton Two Speed R 164 170 173 175 13 _ E R 174 Hydraulic R 180 1412 R 2585 R 2586 E 16600 E 16600 Eaton Two Speed R 183 185 1853 RC 180 16 1415 R 1540 R 1541 E 2613 E 2614 Eaton Double Reduction R 184 190 193 195 19 1416 R 1640 R 1641 E 2695 E 2696 Eaton Double Reduction R 194 200 205 19 Single Reduction R 160 163 165 RG 160 a YD IH IH IH 3OIAWSS NONUL YOLOW ANITY 1418 R 2780 R 2781 E 20500 E 20501 Eaton Two Speed R 190 200 20 1420 R 1810 R 1811 T U 200P T U 200P Timken Double Reduction R 210 38 1423 R 2800 R 2801 T U 300P T U 300P Timken Two Speed R 210 a 37 Continued on following page suot eorzroadsS
4. Drive nut Coil spring A 22646 Fig 6 Axle Shift Unit In High Range Position Motor Lever assembly le Y Power screw Drive nut Trunnion NOUULO GT UE TUI Limit switch Coil spring T Fig 7 Axle Snift Unit In Low Range Position of thespring is raised tofrom 90 to 135 pounds again depending on axle size This additional means is used to shift the axle and when the shift is completed the ends of the spring come together leaving the origi nal tension of 45 to 65 pounds on the spring This preload tension holds the axle in either gear Shift To Low When the button is pushed down the motor is energized so that the screw moves counter clockwise and the nut travels to the top wind ing the spring for a shift to low in the same manner as before PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section H Page 3 SERVICE AND TROUBLE SHOOTING General Information If the electric shift should fail to operate properly the trouble should first be located A very handy toolfor this is a test light con sisting of a light bulb either 6 or 12 volts depending onthe electrical system ofthe truck with two wires a few feet long and small battery clips on the ends Refer now to the wiring diagram Fig 3 and first connect the test light to Point d on the circuit breaker under the dash or hood depe
5. Umen lipids BREMEN d c Miti Sais Axle Shaft Diameter at splines 1 3 1 63 64 1 7 8 4 812 1 7 8 16 4 Number of splines Pinion Cone Centers amount of variation marked on pinion Lubricant Capacity Pints jo en N m N o Axle Ratios 6 13 8 10 6 70 8 86 o e Ld 6 99 8 38 25 10 25 4 5 amp 350 400 800 1100 4 5 amp Pinion Nut Torque Ft Lbs 350 400 800 1100 800 1100 Differential Bearing Pre load Tolalk wa 3 xs 263 005 007 005 007 005 007 See Note See Note See Note Pressure against bearing race when checking rotating torque of pinion cage amp Timken Axle NOTE Tighten one notch each from 000 end play G o8eq 5 E Z T O O zs zs C O 7 UN T s lt O 7 gt Z E gt suotjeotzivadg UVa aAIXV AXLE REAR Specifications Page 6 Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL A 22879 FT LBS WRENCH RN Fr LBS WRENCH EFFORT ON WRENCH TORQUE l foot 200 lbs 2 feet 100 lbs 250 1 1 2 feet 170 lbs 2 feet 125 lbs 200 lbs 300 150 lbs 100 lbs 2 feet 175 lbs 2 1 2 feet 140 lbs 350 53 feet 118 lbs 3 1 2 feet 100 lbs 2 1 2 feet 180 lbs 450 3 feet 150 lbs 3 1 2 feet 129 lbs 4 feet 113 lbs 3 feet 167 lbs 500 3 1 2 feet
6. spur pinion See Fig 4 When the fast axle speed is selected and torque released the shift collar is moved to ward the fast speed spur pinion and atthe same time disengages the splines on the slow speed spur pinion The fast speed spur pinion then revolves as part of the cross shaft to drive the fast speed spur gear During this operation the slow speed spur pinion is disengaged so as to rotate freely on the cross shaft Power is transmitted through the hypoid pinion and gear cross shaft clutch collar fast speed spur pin ion and gear differential and axle shafts When the slow speed is selected and torque released the shift collar moves in the opposite direction disengaging the fast speed spur pin ion and locking the slow speed spur pinion as part of the cross shaft Power is then trans mitted through the slow speed spur pinion and gear differential and axle shafts Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section E Page 2 L LINE MOTOR TRUCK SERVICE MANUAL The design of the shift collar prevents dis engagement until the opposite gear ratio is selected and torque released Adjustments and Clearances Various clearance adjustments are pro vided for both in the axle gearing and shifting mechanism These adjustments once made seldom need attention Where a disassembly job is tobe performed the detailed information found in Shop Talk No 34 will be most helpful Hypoid Pinion an
7. 144 lbs 4 feet 125 lbs 4 1 2 feet 112 lbs 3 1 2 feet 158 lbs 550 4 feet 137 lbs 4 1 2 feet 123 lbs 5 feet 110 lbs 4 feet 150 lbs bun 4 1 2 feet 134 lbs 5 feet 120 lbs 5 1 2 feet 110 lbs Wrench Torque Chart The above chart illustrates the length of the wrench handle A and the effort that must be applied at B when tightening to secure the indicated torque ALVA INTERNATIONAL L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section Page 1l AXLES REAR GENERAL INSTRUCTIONS FOR ALL HYPOID AXLES HYPOID REAR AXLES ALL MODELS All rear axles have a hypoid ring gear and pinion whether single reduction double reduc tion double reduction single and two speed final drive and two speed differential Hypoid gears have a greater inherent torque capacity due largely to the fact that the hypoid pinion is much larger in diameter and the pinion teeth are correspondingly larger than those found in a spiral bevel pinion for the same number of teeth and the same diameter ring gear The hypoid pinion has a longer face because of its offset location It also has larger tooth surface areas and usually has more teeth in instant contact withthe gear It is these design characteristics which contribute to greater strength and quieter final drive operation Be cause of this greater tooth contact it is more difficult to secure correct pi
8. 16 Oil scoop 32 Companion flange 48 Axle housing PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section C Page 2 EATON DOUBLE REDUCTION REAR AXLE The Eaton double reduction rear axles shown in Fig 1 are heavy duty double reduc tion type The primary reduction is through a hypoid ring and pinion gear while the secondary reduction is through a set of herringbone gears Primary Reduction The primary reduction gears are the hy poid type consisting of a hypoid pinion mounted on the forward end of the carrier housing and meshed with a hypoid ring gear which is riveted to an integral flange on the ring geariii shaft This shaft also carries as an integral part the herringbone drive pinion for the secondary reduction Secondary Reduction The secondary herringbone reduction gears Consist of a drive pinion and a mating gear The teeth on the secondary reduction gears are right and left hand spiral cut in line with each other forming a V the apex of which is at the center of the gear face A center cut through the apex breaks the tooth line into two separate and opposed spiral gears each exert ing equal and opposed pressure thus balancing the end thrust Installing New Herringbone Drive Gear Differential Case If new gears are being installed the pilot diameter on differential case drive gear flange should be checked to see that it runs true If i
9. 4i INTERNATIONAL be sure to check the bearing pre load Attach a scale to the end ofa soft wire wrapped around the pinion cage as in Fig 7 Read the scale only when pinion cage is moving rotating torque If first adjustment does not result in correct pre load select a thicker combina tion of spacers to decrease or use thinner combinations of spacersto increase the bearing pre load The rear axle specifications list the correct bearing pre load for these axles Gear Adjustment for Correct Tooth Contact Checking tooth contact is accomplished by means of oiled red lead applied lightly to the bevel gear teeth When the pinion is rotated the red lead is squeezed away by the contact of the teeth leaving bare areas the exact size shape and location of the contacts Gear Adjustment for Lash Generally if original gears are being re installed red leading of teeth will not indicate the same contact as new gears and can be mis leading Gears that have been in service for long periods form running contacts due to wear of teeth therefore the original shim pack should be maintained to check gear lash Gear lash when using original gears can be reduced only to a point of smooth rotation of gears If the gear lash in in excess of maximum tolerance as stated under gear adjustment the lash may be reduced only in the amount that will avoid overlap of the worn tooth section Rotate the gearsand check for smooth or rough opera
10. 66 Differential spider pinion gear 67 Front helical and side gear 68 Rear rear axle helical drive gear 69 Transfer case cover mounting gasket 70 Transfer case cover 71 Transfer case cover mounting capscrews 72 Thrust washer 73 Drive shaft bearing inner 74 Drive shaft nut inner end 75 Rear rear axle drive shaft 76 Shifter fork 77 Shift fork bracket mounting gasket 78 Shift fork bracket retaining capscrew 79 Shift fork lever 80 Shift fork lever boot 81 Shift fork bracket pinion gear thrust shaft companion NOTE Rear rear axle drive shaft inner bearing 73 and nut 74 are identical with mainshaft inner bearing and nut CAUTION The differential must not be held in the locked position longer than neces sary Driving the vehicle on improved or paved roads with the differential iock engaged will subjectthe axles and gears to unnecessary strain The differential lock shift fork is spring loaded and automatically releases the lock when shift lever is released by operator L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section G Page 3 DISASSEMBLY OF POWER DIVIDER AXLE MOUNTED To disassemble the power divider proceed as outlined in the following steps l Remove nine power divider to differential carrier mounting capscrews and lift off the power divider Be sure mounting gasket is also removed 2 Place
11. 9 Adjusting bearing pre load Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section D Page 5 3 Tighten BOTH adjusting nuts one notch each from 000 and play to pre load differential bearings 4 Tighten bearing cap stud nuts to specified torque L 100and R 100 Axle Rear Axle Specifications 5 Install adjusting nut locks capscrews and lock wires Thrust Block Installation Turn carrier assembly to bring back face of ring gear facing upward and install the thrust block as follows l Place thrust block on rear face of gear and rotate gear until hole in thrust block is aligned with the adjusting screw hole NOTE A light coating of grease placed on the thrust block face will serve to hold the block in position on the rear face of the gear 12 E li Adjusting screw E ox EE 19697 Fig IO Adjusting clearance of thrust block Turn adjusting screw out of carrier 4 turn to obtain 010 to 015 inch clearance 2 Install adjusting screw and lock nut Tight en adjusting screw to force thrust block against gear then back off one quarter 1 4 turn and lock securely with lock nut Fig 10 Clearance between back face of gear and thrust block is 010 to 015 CAU TION Be sure that the adjusting screw end is seated properly in the thrust block hole PRINTED IN UNITED STATES OF AMERICA Lubrication 1 Remove inspection a
12. AXLE REAR Section B Page 3 Gear Tooth Contact To secure best possible tooth contact use SE 1065 pinion setting gauge and follow in structions under this heading Section A page 2 Check results obtained by making a paint impression test of tooth contact See Gear Adjustment for correct tooth contact Paint Impression Method Section A page 3 Lubrication An oiling system is provided to supply lu bricant within a half a turn of the truck wheels to the essential places during conditions when splash and dip alone would be insufficient A heavy coating of oil is picked up by the oil collector drum and transmitted to the oil scoop The oil scoop scrapes the oil from the drum and splits it into two courses One half of this lubricant goes to the pinion bearings the other half to the right hand differential and planetary unit to the left differential bearing and then returning to the reservoir Whenever a two speed differential new or rebuilt has been installed in the axle housing fill the oil reservoir to bottom of filler plug opening and replace plug Then add one addi tional pint of lubricant using filler hole provided at top of carrier housing just above pinion cage Use a hypoid gear lubricant available as ElcoGear Safety 28 or its equivalent A num ber of hypoid lubricants are prepared by repu table companies which contain Elco additive concentrates Viscosity of the hypoid lubricant shouldbe SAE 90 When high
13. L1 18 19 20 2l Gls 23 24 AD 26 2T 28 PRINTED IN UNITED STATES OF AMERICA Bearing inner Hypoid pinion Bearing spacer Bearing outer Companion flange Washer Nut Cage capscrew Slinger Seal Washer Pinion cage Shims Carrier Carrier capscrew Gasket A 22814 Axle shaft Bearing adjuster lock Bearing adjuster Bearing cap Thrust washer Side gear thrust washer Side gear Differential pinion Pinion thrust washer Differential case Pinion gear spider Ring gear case Idler pinion pin Idler pinion gear Axle housing Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section B Page 2 L LINE MOTOR TRUCK SERVICE MANUAL EATON TWO SPEED REAR AXLE The two speed rear axies are full floating hypoid drive type having four planetary gears which mesh with an internal gear on the hypoid ring gear The primary reduction is accomplished through the hypoid ring gear and a straddle mounted hypoid pinion The secondary reduc tion is accomplished with a sliding clutch serving to lock or unlock the planetary gears serving The correct servicing of this unit as is true with any mechanical equipment is impor tant to satisfactory operation and life Servic ing the two speed unit does not require special tools The ordinary equipment found in most shops is sufficient for this work Use the fol lowing step by step procedure for d
14. Page l REAR AXLE IDENTIFICATION CHART ocz aT ae 89 ee O O eee eee oH 22H o6r aT 211111111 1111 T 111 i PP TTT be px 241 lil LLLI A R GAO a L erI5 j Pm e MI L j ED dl e DD mL LLLI ILLE A 1 o er T gt Ir 1 jilll LLLLI L LLL LL LLLI ILI t PP vet T e l gv T 1111 1 111 OSTOT f ILL 1111 Loser TT MI 1 egrrT tit px ply III L Ll cera Iie TITT 1 1 111 1 LLLL MAA AAA A IL ee ASS LL AL eT 111 1 LLLLLL O e e e eT eee 21 eee OLT ijo T LL 9T p S O L O O r s LLL sot Tt P E P ET LLLLL DL LLLL PET CA e ET X BEIGE IEEE BEEERNEERHENRE LostWT 1 S LELLDEL LL LLLL estT feet TT L LL T LL LLL LL LL LLLLL lost 111 eT TT LL LLL LLL LL rat o TT TT EE TT ly oet T ee ee eee X LLLILLLLELLLELLL TE CIL LLLL oet TT LL LL LLLI LLL LL LLLLL LL LL OZI WN I EA IS dela 1a sf Al ok ett ad c Bigi O A SS A DA E e gt gt amp AA A n EE Sigil giam a hee tp m ggaigiag aia E l E 3561858 8 818 8 8 9 35 9 98 8 8 OE A 31553 s SH Suae o do an A4 jo g 9 999 O ORIS s sl 5 3 ojh A 3 3 3 3 3 3 38 3 3 rit tl il tll o Jo a O TITT D TTT T HT BT TT T ol o Q ga
15. REAR L LINE MOTOR TRUCK SERVICE MANUAL Mes 6 1 i 8 7 18 W 15 16 17 i t Ap pr du Lj LAAN DIETS LA Aa Y VEN SNE 22 VY Ge Reo oi HEEE S Ei ANS A qi AN Y fd y 21 San yt ATH 7 Y 28 wA D ZU 30 A Oh RN g NENEZ ily IZN 2S I N a4 A E ENS NEL SL al 4 NIE 58 er A N MN W gt gt Xn A 38 39 EE T mE NE 4 are 19 i LAM 0 SY aad 7 gt ZU MLB FS SST 54 Y 55 XL See Legend on following page sp Z 49 a 77 lt gt X Q A E EUA E reo ees A S ASS INA SES AV SL LL LL ARAN SS u PEZ f 2S SS INS sem AN eile Y OE 45 Y 46 48 B 4745 Fig Details of axle mounted power divider mounted on forward rear axle AXLES RF 1475 RF 1575 RF 1685 FOUR WHEEL AXLE MOUNTED POWER DIVIDER The above axles have a power divider built as an integralpart of the differential assembly This results in a more simplified tandem axle design with less moving parts The compact ness of the combined power divider and differ ential makes possible the use of fewer propeller shafts and eliminates the need for a propeller shaft hanger at the rear of the vehicle The PRINTED IN UNITED STATES OF AMERICA power from the engine is delivered through the transmission and auxiliary transmission where the truck is so equipped to the power divider which as the name implies divides
16. Remember It is essential to arrive at a measurement as nearly equal the corrected cone center as possible h DO NOT FAIL TO VERIFY ACCURA CY OF THE ADJUSTMENT SECURED WITH THE SE 1065 gauge by checking the gear tooth contact using the paint impression method as set forth under General Rear Axle Hypoid Pinion and Ring Gear Adjustment which follows GENERAL REAR AXLE HYPOID PINION AND RING GEAR ADJUSTMENTS PAINT IMPRESSION METHOD The following general instructions and suggestions are for the benefitof those service stations not equipped with an SE 1065 pinion setting gauge Bear in mind that the accuracy of the adjustment obtained with the following procedure is dependent upon the skill of the operator Hypoid gears when mounted should show a bearing toward the toe or small end of the tooth neveratthe heel or large end the reason being that itis practically impossible to make gears and gear mounting rigid enough so that there will not be some slight deflection when fullloadis applied This always has a tendency to cause the bearing to come on the heel of the tooth and when gears are adjusted so that the bearing is toward the heel of the tooth it re sults in a concentration of load on the top cor ner of the heel and breakage will follow PRINTED N UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR IRUCK SERVICE MANUAL AXLE REAR Section A Page 3 Checking tooth co
17. Remove lockwashers cover cover and gasket Drain lubricant from nousing screws PRINTED IN UNITED STATES OF AMERICA Lever assembly Power e screw Limit E switch Moo Trunnion a A y 3 Drive nut Coil spring A 22646 Fig il After removal of cover note that nut and lever assembly will be at either top or bottom of screw depending upon position in which the shift button was last used Cover Gasket Drive screw Nut in center 8 Detent spring A 22647 Fig 12 By turning drive screw run nut from either top or bottom position to center of screw IMPORTANT This step is essential to prevent damage to drive nut contact bumper lo cated in center of lower or inner trunnion The nut must be inthe center position upon assembly also Lever assembly Trunnion contact bumper is on opposite trunnion Bearing cover Fig 13 Pull assembly out pivot pin and remove lever Donated by John amp Susan Hansen For Personal Use Only AXLE REAR MA A a L LINE MOTOR TRUCK SERVICE MANUAL NOTE When reassembling lever assem bly make certain that the contact bumper on nut is toward the switch Bearing Screwdriver A 22644 Fig 14 Remove drive screw bearing cover and push down on screw assembly until bearing is free of housing Insert screwdriver in drive slot of screw and remove bearing retainer nut and bearing Lock nuts A 226
18. Riveting Jig SE 1575 is available and is designed for use with hydraulic or mechanical press equipment The following pressures are recommended for differential ring gear rivet installation PRESSURE BIG awh ew eee wa eee de 12 to 15 379 ke we ee Bus 17 to 20 7 16 T 30 to 35 TA sume SIUE E 2 45 to 50 9 16 ae ha eRe 2 2 60 to 70 A we 60 to 70 Axle Shaft Removal Timken Axles Axle shafts are attached to the wheel hubs by studs and nuts at the flangedenc Stud holes in each axle shaft flange are taper reamed to receive split tapered dowels When disassembling the axle some of the bearing cage studs or axle shaft studs may turn loose from the housing rather than at the nuts When the axle is reassembled the nuts should be removed from the studs and the studs re placed in their tapped holes before installing the cage or carrier When removing the axle shafts from the Timken axle remove the stud nuts and lock washers and proceed as indicated in Figs 19 20 2l A 1007 Fig 19 Using a heavy hammer strike sharply on the center of the flange of the axle shaft This will unseat and loosen the tapered dowels in each stud hole TAPERED DOWELS E SOS all OS Ns SSS AXLE FLANGE A 10072 LOCK WASHER Fig 20 Remove the tapered dowels Note When reassembling there must be a slight clearance between the lockwasher and axle shaft driving flange Excessive wear onstuds dowels or ho
19. The assembly of the center cross bar and saddle is shown in Fig 2 The sleeve is lo cated in the saddle and is locked in place by two thru bolts Inside the steel sleeve there is a center cross bar which must rotate freely in the sleeve Inthe LF 170 the center cross bar is solid steeland on the LF 190 and LF 210 it is a steel tube In removing the tube or cross bar itis first necessary to jack up the rear end of the truck remove the spring shackle pins remove the two equalizer beam end bolts then remove the saddle equalizer beam and the springs The tube or cross bar is then removed from the supporting sleeve Equalizing Beam Ends Equalizing beam end constructionis shown in Fig 3 The beam end ball is supported in a two piece bronze socket which is pressed into the beam end Lock bolts prevent the sockets LOCATION OF LUBRICATOR RIGHT tert IT BEAM BEAM TA ZA Z INS een C O NNN SHAFT SEAL WASHER BUSHING A 16155 Fig 2 Cotter pin Felt retainer Nut Su Lockwasher Socket Roy N Beam end ball Plain washer Equalizing beam N 4 Felt seal Spring Socket lock holt Equalizing beam Lubricator Socket upper half gt Socket lower half A 22712 from moving and felt seals with spring retain ers are used to guard against leakage of lubri cant and entrance of dirt When replacing a socket or ball assemble both halves of the socket to the ball
20. atmospheric tem peratures above 100 F prevail SAE 140 may be used See Lubrication section A d Shift fork shaft i Electric shift unit Lubricant Dig Lubricant plug Pinion cage N i aa cd a r7 E s adi u E sl P 23435 CHEN i NET AS Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only AXLE REAR L LINE MOTOR TRUCK SERVICE MANUAL n DOUBLE REDUCTION AXLE EATON Qo 1 C tn amp C Bo 32 31 30 29 28 27 26 25 24 4 22813 Fig Double Reduction Axle Eaton l Carrier gasket 17 Spring and plug 33 Cotter pin 2 Carrier 18 Axle shaft 34 Nut 3 Herringbone gear 19 Countershaft bearing 35 Washer 4 Gear rivet 20 Pinion countershaft 36 Cil seal 5 Oildistributor disc 21 Cage capscrew 37 Bearing cage 6 Case flanged half 22 Bearing cage 38 Cage shims 7 Case bolt and nut 23 Carrier capscrew 39 Oil passage 8 Thrust washer 24 Cage shims 40 Hypoid ring gear 9 Bearing cap 25 Oil reservoir 41 Oil distributor disc 10 Cap stud 26 Hypoid pinion 42 Oil scoop ll Lock ring 27 Bearing inner 43 Oil scoop capscrew 12 Bearing 28 Bearing spacer 44 Spider pinion 13 Side gear 29 Bearing outer 45 Pinion thrust washer 14 Thrust washer 30 Washer 46 Case plain half 15 Lock ring 31 Slinger 47 Spider
21. cone center Figs 2 3 and 4 Cone Center Specifications Matched and mated hypoid ring gears and hypoid pinion gears are furnished both for service and for production Mated gears are marked with figures showing the amount of variation from their theoretical cone center Theoretical cone center of bevel drive gear and pinion Fig 2 Fig 2 illustrates a hypoid ring gear and pinion adjusted to theoretical cone center wherein the cone centers of both gears coincide The specifications in this case would be the distance from the line A B Fig 1 drawn through the center of the hypoid ring gear to the ground face of the hypoid pinion on center line E F On some axles the pinion is lo cated above the center line C D Fig l In these cases the term hypoid still applies Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 2 Cone center of bevel drive gear Cone center of pinion Fig 3 Fig 3 illustrates a setting wherein the mating of the gears has necessitated the pinion cone center being farther than the ring gear center The pinion marking in this case will be minus because the distance from the ring gear center is less Cone center of bevel drive gear Cone center of pinion LD A 22801 Fig 4 illustrates a condition where the mating of the gears required the pinion cone center to be farther OUT The pinion marking will be plus becau
22. design and construction over conventional rear axles for on highway and off highway service in heavy duty motor trucks These axles provide increased torque ca pacity and eliminate the former need because of specific chassis requirements for both top mounted and front mounted double reduction final drive units The differential carrier on the S 200 P and U 200 P axles is mounted at an elevation which is a satisfactory compro mise between the two extremes The S 200 P and U 200 P rear axles em ploy the same differential and carrier assem blies They differ only in that the rear axle housing of the S 200 P is of lighter construc tion for the S 200 P axle is not intended for off highway service Drive Unit The drive unit or differential carrier as sembly is mounted on the sloping front face of the axle housing and is readily removable for periodic inspection PRINTED IN UNITED STATES OF AMERICA The differential bearing legs are dowelled in the axle housing to elim inate deflection under torque load Pinion Shaft Location The pinion shaft is located at an elevation midway between that used on the front mounted type axles where the pinion shaft is on the axle center line and that used on the top mounted type axles where the pinion shaft is considerably above the axle center line Fig 1 Final Drive The final gear drive consists of a large diameter hypoid bevel gear and bevel pinion for thefirst reducti
23. dirt PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section G Page 5 Y Oa Cotter pin pum Torque rod ball Spring e e to Felt seal o Felt retainer Sock ockets y AS Torque rod NS p Gy PE ie SL ITZ LL ue Cap screws Lubricator Torque rod KO gt A 22729 Fig Y Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section H Page 1 ELECTRIC SHIFT EATON USED ON EATON AND TIMKEN TWO SPEED AXLES Shifting motor assembly Rx 4 s Le ES A rA 7 l Lubricant HN plug TUBE Fig Electric Shift Unit speed axle 22896 Mounted on two Description The electric shift device consists in the main of an electrically operated shifting fork and shifting unit located on the two speed axle Fig 1 The shift fork is activated by a two directional coil spring and lever assembly Figs 6 and 7 The purpose of this spring and lever assembly is to move the shiftfork quick ly into the high or low speed position when gear load is momentarily removed from the differential The actual shifting or gear movement is performed by the coil spring located in the housing of the electric shift unit The coil spring which performs the shift must be plac
24. parts in a cleaning solution to remove all dirt and sludge deposits Be sure transfer case is free of any loose metal particles Carefuily inspect all parts and replace any that are doubtful as to further satisfactory service ability To reassemble the power divider the exact re verse procedure as outlined for disassembly should be used However it is advisable to observe the following precautions Be sure all sealing surfaces are free of nicks and that the old gasket material has been com pletely removed NOTE The transfer case to differential carrier mounting gasket is 008 thick The differential case was marked as to for ward side and also for correct reassembly of the two case halves It is of utmost importance that the eight differential case mounting bolts be so installed that the bolt heads are also on forward side of differential assembly after installation in power divider NOTE Female half of differential case should be forward Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section G Page 4 L LINE MOTOR TRUCK SERVICE MANUAL To secure the pinion bearing pre load reading specified in the Rear Axle Specifications for this model axle see Pinion Bearing Adjustment for Correct pre load Make a bench assembly of bevel pinion shaft bearings spacers and pinion bearing cage Place all parts in the same position as in the final assembly The pinion shaft assembly may now be placed in
25. preload spring Reassembly of the axle shift unit is the reverse of disassembly PRINTED IN UNITED STATES OF AMERICA SHIFTING INSTRUCTIONS FOR EATON TWO SPEED AXLE ELECTRIC SHIFT TO SHIFT INTO LOW SPEED RATIO l Keep accelerator pedal down push button down 4 To complete shift disengage and reengage clutch as quickly as possible holding accelerator pedal down or release and reopen accelerator as quickly as possible TO SHIFT INTO HIGH SPEED RATIO l Keep accelerator pedal down pull button up 2 To complete shift release accelerator and pause until shift is completed SPLIT SHIF TING To shift to next higher gear in the trans mission and at the same time from high to low speed axle make the transmission shift in usual way and just before engaging clutch push the button down To shift to next lower gear in the trans mission and atthe same time from low to high speed axle pull the button up then complete the transmission shift in usual way IMPORTANT l Always keep accelerator down when con tool button is moved except when split shifting to low speed ratio 2 For best results start loaded trucks in low speed ratio Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section H Page 8 hs a 12 13 14 15 e WO 00 3 y UA WH Ww L LINE MOTOR TRUCK SERVICE MANUAL GF ey 2 8 B 4746 Fig 20 Electric Shift Parts Identifica
26. than the opposite wheel To do so might cause serious damage to the differential spider and gears Use SCL EP gear oil or a multi purpose gear lubricant suitable for hypoid axles and supplied by a reputable refinery SAE 90 for cold climate and SAE 140 for warm climate When reassembling the differential gears thrust washers cross shaft spur gears and bearings lubricate the wearing surfaces with a light coat of specified axle lubricant This will help provide initial lubrication INSPECTION HOLE COVER GASKET HYPOID PINION lt a OIL PLUG Fig 8 Insert one pint of lubricant in pinion cage before starting new truck or after over haul Electric Shift The electric shift mechanism used on all Timken double reduction two speed axles is identical with the electric shift used on Eaton two speed axles For detailed information see Electric Shift Section H AIDA INTERNATIONAL Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section F Page l DOUBLE REDUCTION AXLE TIMKEN 200 SERIES AXLES See Shop Talk No 25 for complete illustrated disassembly Hypoid gear Hypoid pinion Differential case Helical gear Helical pinion m Dx Y way un s MONA A 10067 Fig Double Reduction Drive Unit Timken The Timken S 200 P and U 200 P series double reduction rear axles Fig 1 introduce improvements in
27. the power between the two axles A differential unit is included in the power divider to com pensate for the difference in speeds between the two axles This difference in axle speeds is brought about by wheels slipping on either of the axles or slightly different tire diameter due to tire wear Both rear axles on six wheel 6x4 trucks have the same axle differ ential ratio Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section G Page 2 L LINE MOTOR TRUCK SERVICE MANUAL Legend For Fig 1 Mainshaft Companion flange retaining nut Companion flange Thrust washer Slinger Felt Oil seal Bearing cover retaining nut Bearing cover 10 Bearing cover gasket 11 Mainshaft bearing front 12 Differential lock 13 Transfer case cover 14 Thrust washer 15 Forward axle bevel pinion shaft 16 Pinion bearing cage cover 17 Outer pinion bearing nut 18 Pinion bearing cage capscrew 19 Pinion bearing cage cover seal 20 Pinion bearing cage 21 Shims 22 Thrust washer 23 Pinion bearing outer 24 Pinion bearing spacer 25 Pinion bearing inner Oo wo OW W t t5 e e a gt X 26 Spacer 21 Differential spider thrust washers power divider 28 Transfer case 29 Forward axle helical drive gear 30 Oil seal assembly 31 Pinion bearing 32 Pinion bearing sleeve 33 Pinion bearing sleeve set screw 34 Power divider to different
28. the hypoid pinion shaft in the carrier housing This shaft is a one piece steel forging consisting of an integral helical drive pinion gear in the center The hypoid ring gear is aligned with key in shaft before pressing gear onto shaft PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section F Page 3 To remove the cross shaft it is necessary to first remove the differential and helical ring gear assembly second withdraw the hypoid ring gear when being removed Do not remove universal joint flange Then remove both bearing cages move shaft enough to allow bearing at ring gear end of shaft to clear the carrier housing and tilt shaft to rear for re moval from carrier The correct bearing pre load is obtained by adding or removing shims at shim pack under the cross shaft bearing cage at end op posite hypoid ring gear Use orignial shim pack plus a new gasket when reinstalling ori ginal gears To measure correct bearing pre load follow method outlined for Timken Double Reduction Two Speed Axles Section E Fig 3 Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only AXLE
29. 020 in thickness over end of cage and place cage and pinion assembly in carrier it being necessary to match flange holes in cage since one hole is out of equal spacing to assure prop er position of cage Next assemble two cage bolts only until gear setting is completed Assemble differential and bevel gear assem bly and place bearing cap and adjuster in posi tion Tighten bearing cap bolts and back off slightly to provide sufficient looseness to allow turning the adjuster for a temporary backlash adjustment of approximately 010 After this adjustment has been made tighten each bearing adjuster snug then give them a final tightening operation drawing them up to secure the 005 to 007 total bearing pre load This is im portant in order to make certain that the bear ings are seating properly IMPORTANT Hypoid drive pinion oil seals must be soft and pliable before being in stalled if the seals have become dried out and hard while in stock use kerosene and work it in thoroughly When seal has become soft and pliable dip it in hot oil and work this oil in thoroughly PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 7 Press ram Staking tool Pinion bearing Pinion A 22727 Fig I7 Using the pinion staking tool Pinion Bearing Straddle bearing The straddle pinion bearing is held in plac
30. 24 Fig 15 Remove two lock nuts from switch ter minals and remove wires y n e Housing Motor Motor cover A 22649 Fig 16 Remove three motor retainer screws remove cover and gasket and pull motor assem bly out of housing D pea EPIS Automatic switch assembly A 22625 Fig 17 Remove jam nuts switch retainer nuts and fiber washers from back side of hous ing Remove switch center screw and lift out switch assembly Lever and Spring Assembly Good practice is to perform the disassem bly and reassembly of the lever and spring unit only when necessary to replace one of the parts Turn lever This lever clockwise remains and pull stationary Spring Fig 18 Place lever assembly in vise as shown Turn spring winding lever clockwise and pull then allow spring to unwind This operation will permit disassembly of the levers and spring IMPORTANT Do not disassemble this unit until necessary to replace one of the parts Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section H Page 7 End of spring to be located 43 A in notch Torsion spring i Fig 19 l When reassembling the spring and levers locate parts as shown Fig 19 Turn lever and spring clockwise bringing end of spring around end of lever nearest vise Push end of spring into notch of actuating lever nearest vise This will
31. 5 16 E 18 19 20 el 242 correct positioning of gear on reassembly When reassembling hold adjuster and bearing cap up away from threads in bore of carrier unit cap bolts are started Drop cap the threads of the adjuster and those in carrier will mesh freely After removing bearing caps tip up left hand end of planetary unit and lift out Remove pinion bearing cage capscrews Using a suitable puller remove pinion assembly from carrier May also be re moved by using a brass drift and tapping lightly from the inside Note shims under pinion bearing cage Remove pinion shaft nut and slide off com panion flange Lift off pinion bearing cage bearing washer and spacer Drive off pinion bearing cage by tapping lightly between teeth of pinion alternately on opposite sides ofinner race CAUTION Exercise care so as not todamage bearing during this operation Remove pinion bearing cone and washer cage assembly Take out pinion bearing cage cork Replace this cork with every repair Remove lockwires nuts and bolts from planetary unit support case Tap alternately on opposite sides of ring gear with head of rawhide hammer until gear is free of flange on support case When reassembling use two bolts to as sure proper alignment of bolt holes Lift off left hand support case and bevel drive gear Pry off high speed clutch plate and take out idler pinions and pins Lift out entire d
32. AR AXLE GROUP SPECIFICATIONS Axle identi ication Chart ainia doe SO OR NS Ee ARS AAA AA Specifications CEREAL Aa ee e SET bs a Wrench TOrGue Charl de ea AA AAA AAA AAA ae P9 SECTION A GENERAL INSTRUCTIONS FOR ALL HYPOID AXLES Axle housing breather T D box x ww A EX E c ETE Tm AXIS nat TemoValos scs o9 amp okOROP Un deed eee oO WR dor AAA oC RR es 8 Cone center Specifications 4 bd Kk Se esa a 9353 9 439 9 l Differential assembly L 110 Lel120 4 ax 43 wee He ewe X2 wa ewe X9 3x X SSS l Gear adjustment for lash orse raro a ob ege o ee Gear tooth CONTAaCO acarrea AA AAA AAA Hypoid rear axles ion 3 34 wx sa DEA LETERE Ew ode GOES Se Lubrication isd 0 OPER SES ORAL OSE EG EWS OME ERAN Os Pinion bearing adjustment aded 6S 4D G hok aS EEDA eS ow Oe eww os Pinion Setting 14 4 bd ewe os CAR OSH SES AAA arr Ring Bear TIVOS acia as WCG oa AAA s Single reduction axles sectional views Straddle mounted pinion bearing eee ee es T TTTTIITITE TR SECTION B 11 1 NM OP ATOR KE OON OO TWO SPEED AXLE EATON IOSCPIDLLO 5 eee wee cx 90 ue w ww SOEUR ON UR RRR ER aa Lubrication ios x ws E e wok d Wed 4 Be x3 cw ox x zw x x x p ow oa Sectional VIW 5 twee AAA Wr O nN SECTION C DOUBLE REDUCTION AXLE EATON Descr Olr ea eco wu xw Ao EOXCX R X ERE amp o0 305 4 4 40 E EC OG 4 30 o3 8 0 05 9 e de AE d Differ
33. L R 1060 OR R 1070 A 22643 Fig 26 Sectional View of Hypoid Rear Axle Companion flange Propeller shaft mounting nut Propeller shaft mounting nut washer Pinion shaft bearing oil seal Pinion bearing cage to carrier capscrew Pinion bearing cage Pinion bearing outer Pinion bearing spacer Pinion bearing inner Hypoid pinion gear straddle mounting Pinion bearing Differential side gear Axle housing Differential bearing adjuster lock Differential cross pin Hypoid ring gear Hypoid ring gear rivet Differential pinion Axle shaft Differential bearing adjuster Differential carrier to housing gasket Differential carrier to housing capscrew Differential roller bearing Differential center block Differential cross pin retaining pin Differential case Differential carrier housing Pinion bearing cage shim NOTE Rear Axle R 1070 is identical with above description except differential center block 24 is not used PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 12 ODN OOP WN r L LINE MOTOR TRUCK SERVICE MANUAL A Y IN IN SINGLE REDUCTION HYPOID AXLE MODELS R 1165 R 1170 R 1440 R 1470 R 1530 R 1555 R 1630 ZG o0 0 A 22817 Fig 27 Sectional View of Hypoid Rear Axle Axle housing Hypoid ring gear Differential bearing cap Differential bearing cap moun
34. LOW SPEED PINION A 15790 Fig Two speed Double Reduction Drive Unit Description The Timken Two Speed Double Reduction Final Drive Differential Fig 7 provides two gear ratios actually two full size final drives in one unit a fast ratio for maximum speed and a slow ratio for maximum pulling power This feature enables the truck driver to use the proper axle gear combination required for speed load and road conditions Operation The first reduction in the Timken Two Speed Double Reduction Drive Axle is through a heavy duty hypoid bevel pinion and gear The hypoid bevel pinion and gear set operates in conjunction with either of two sets of wide face helicalspur gears and pinions of different ratios This second reduction is selective between a fast or slow ratio The bevelpinion is mounted on two tapered roller bearings in a pinion cage The bevel gear is locked on thecross shaft by a key The cross shaft is mounted on tapered roller bear ings and carrier two free rolling helical spur pinions Both spur pinions engage helical spur PRINTED IN UNITED STATES OF AMERICA gears attached to the tapered roller bearing mounted differential On the inner side of each of the spur pinions are integral splines On thecross shaftare two rows of splined teeth A shift fork actuated by an electric power shift unit moves the shift collar on the splined portion of the cross shaft to engage the splines on the fast or slow speed
35. Pinion Mounting Overhung Straddled Overhung Overhung Axle Shaft Diameter at splines 2 1 8 2 3 8 2 3 8 2 3 8 2 3 8 1 3 4 1 3 4 1 3 4 ps p oSgeq suortjeotrjto2edg YA VaIYN A IXV Number of splines B e 04 RT ES Z T1 O O zs AJ C O IN Un T s lt O T gt Z E gt E Pinion Cone Centers amount of variation marked on pinion Lubricant Capacity Pints Axle Ratios o 9 76 Pinion Adjustment Press pressure tons 10 Cage Rotating Torque Scale Reading Lbs 10 25 10 25 Pinion Nut Torque Ft Lbs 400 500 700 900 700 900 700 900 700 900 280 300 DM Differential Bearing Pre load Total je cas oe os i bw woe els 005 007 See Note See Note See Note See Note Pressure against bearing race when checking rotating torque of pinion cage amp Timken Axle NOTE Tighten one notch each from 000 end play 6 13 8 10 6 70 8 86 005 2 007 005 007 VOINAaWY JO SALVLS GALINA NI OCALNIMd Pinion Adjustment Press pressure tons 10 10 Cage Rotating Torque Scale Reading Lbs 10 25 10 25 280 300 Donated by John amp Susan Hansen For Personal Use Only REAR AXLE SPECIFICATIONS REAR AXLE MODEL R 2475 R 2580 R 2585 R 2590 R 2600 R 2740 R 2741 R 2800 COde s ko tad ci ow 1426 1413 1412 1427 1414 1422 1423 s i pem TT P i ls B diu
36. REAR AXLE SPECIFICATIONS RF 1575 RF 1685 REAR AXLE MODEL R 1530 R 1555 R 1630 Forward Rear Forward RF 1576 RF 1577 RF 1686 COJO x d wx de e36 inadi 1429 1408 Type Semi or Full Floating Full Full Pinion Mounting Straddled Axle Shaft Diameter at splines diia i pes OUT o ow ood fae m Pinion Cone Center amount of m Z T O O A AJ C O IN UN T A lt O m lt gt Z C i gt variation marked on pinion 2 937 Lubricant Capacity Pints 2 18 Axle Ratios 454 5993 5 756 5 571 6 940 6 5 7 166 Pinion Adjustment Press pressure tons 10 10 10 10 10 10 10 Cage Rotating Torque Scale Reading Lbs 10 25 10 25 10 25 10 25 10 25 10 25 10 25 Pinion Nut Torque 280 300 350 400 350 400 280 300 600 900 400 500 350 400 Differential Bearing Pre load Total 005 007 005 007 005 2 007 005 007 005 007 005 Z 007 005 2 007 005 2 007 Pressure against bearing race when checking rotating torque of pinion cage c oSeq suot e2ijt22adg UVAAATXV Donated by John amp Susan Hansen For Personal Use Only REAR AXLE SPECIFICATIONS REAR AXLE MODEL R 1640 R 1730 R 1731 R 1740 R 1810 R 2465 R 2466 R 2470 Code m 1416 Li 1419 1421 1420 1410 1411 1425 Full
37. XLE SPECIFICA TIONS un TE nr Es E RF 1475 o p REAR AXLE MODEL R 1060 R 1070 R 1165 R 1170 R 1440 R 1470 e E Forward Rear o gt RF 1476 RF 1477 o7 Code 1402 1433 1403 1404 1405 1428 1428 Type Semi or Full Floating Semi E s m Am o p oo own Pinion Mounting Straddled Straddled Straddled Axle Shaft Diameter at splines 1 9 32 9 32 1 BUR 1 33 64 1 3 4 1 3 4 3 4 3 4 Number of splines J 10 e ow ade we 16 Pinion Cone Center amount of variation marked on pinion 2 609 2 609 2 984 2 984 3 253 3 253 4 156 3 253 8 Axle 8 E 6 166 6 166 7 166 7 166 10 25 10 25 10 25 10 25 10 25 10 25 10 25 Pinion Nut Torque Ft Lbs 200 230 200 230 200 230 200 230 230 00 230 280 300 350 400 280 300 Differential Bearing Pre load E A ss paali 005 007 005 007 005 007 005 007 005 2 007 005 007 005 007 Pressure against bearing race when checking rotating torque of pinion cage Lubricant Capacity Pints Hi A um Axle Ratios P 3 73 4 777 Pinion Adjustment Press pressure tons m s Z n ES o O zs ms C O Us UN T y lt O Mm x J Z G gt Cage Rotating Torque Scale Reading Lbs 10 25 P 005 2 007 Un p UJ YOIH3NY 30 SILYAS GALINA NI G3LEINIHd Donated by John amp Susan Hansen For Personal Use Only
38. age and BEFORE THE AXLE IS SUBJECTED TO HEAVY LOADS Good practice is to check the lubricant level in the axle housing then JACK UP BOTH rear wheels and operate the vehicle in high transmission gear at approximately 25 miles per hour for five minutes This will assure thorough lubrication of the gearing be fore the unit is placed into service Do not allow one wheel to race faster than the opposite wheel Where the axle pinion cage is provided with a plug at the pinion cage insert one pint of lubricant to provide initial lubrication for the pinion bearing Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 10 L LINE MOTOR TRUCK SERVICE MANUAL Specified Lubricant For Hypoid Axles For hypoid axles not Eaton use SCL EP gear oil or a multi purpose gear lubricant suit able for hypoid axles and supplied by a reputa ble refinery SAE 90 for cold climate and SAE 140 for warm climate For Eaton hypoid axle use a hypoid gear lubricant available as Elco Gear Safety 28 or its equivalent A number of hypoid lubricantes are prepared by reputable companies which contain Elco additive concen trates See Lubrication section A NOTE Whenreassembling the differential gears thrust washers cross shaft spur gears and bearings lubricate the wearing surfaces with a light coat of the specified axle lubricant Differential Assembly L 110 and L 120 The L 110 and L 120 Series Trucks u
39. al installed The seal wiper and cork gasket are pressed over the end of the axle tube Be care ful not to bend or damage the seal wiper when installing Fig 3 The seal retainer assembly is placed over the axle flange studs as shown in Fig 4 using a gasket on both sides of the seal retainer as sembly The rear wheel inner seal construction is illustrated in Fig 5 Before installing the inner seal check the location of the bearing and oil seal spacer to be certain that the seal lip on the oil seal assembly faces toward the oil seal wiper ring in the wheel hub as shown Special adapters should be used in seal installation as described in Service Bulletin B 97 1946 and Addendum No 1 pi Axle housing iE t Y Wiper ring vo M rite S 437 bs a VA aream nt Gasket 4 196345 Fig 3 llustrates wiper ring and gasket A 19634 Fig Y Bearing Oil seal assembly Spacer Bearing and oil seal spacer Axle housing A 15996 Fig 5 Rear wheel inner seal Lubrication l Before starting new truck and after over haul remove pipe plug at pinion cage and insert one pint of specified lubricant 2 Fill axle housing to correct level with specified lubricant The various axle ca pacities are found in Lubrication Section 3 Jack up BOTH rear wheel and operate ve hicle in high transmission gear at approxi mately 25 miles per hour for five minutes to assure prope
40. and press the assembly into the beam end Make sure that the grease hole in the socket indexes with the lubricator hole in the beam end THIS IS VERY IMPORTANT Both sides of the socket must be counterbored flush with counterbore in beam so that the socket lock bolt and plain washers will prevent the socket from shifting Install felt seals and spring retainers before assembling the beam end to the bracket The beam end bolt nut should be drawn up as tight as possible and securely locked with a cotter pin Torque Rods Figure 4 illustrates the torque rod end assembly used on six wheel L line models Shims are used between the ball sockets to provide proper adjustment To disassemble remove the torque rod ball cap then tap the torque rod near the bronze socket and the lower half of the socket will slip out The ball stud nut should then be removed and the ball stud driven out of torque rod Reassemblyis accomplishedin the reverse manner Press upper half of ball socket into torque rod and insert ball stud Install shims approximately 035 and insert lower half of socket Assemble cap and tighten securely Check movement of ball stud using a piece of tubing about 16 long as a lever If ball stud moves too freely remove a 005 shim and if too tightly add another 005 shim Only a slight drag should be felt NOTE Be sure that the felt seal retainer and spring are replaced to prevent leakage of grease and entrance of
41. arrow contact A HIGH NARROW CONTACT IS NOT DESIRABLE If gears are allowed to operate with an adjustment of this kind noise galling and rolling over of the top edges of the teeth will result To obtain correct contact move pinion toward bevel gear to lower contact area to proper location This adjustment will decrease backlash between pinion and bevel gear teeth which may be corrected by moving HE SHORT TOE CONTACT A SHORT TOE CONTACT IS NOT DE SIRABLE If gears are allowed to operate with an adjustment of this kind chipping at tooth edges and excessive wear due to small contact area will result To obtain correct contact move bevel gear away from pinion This will increase the length bevel gear away from pinion Backlash of 006 to 012 is correct Fig 8 A LOW NARROW CONTACT IS NOT DESIRABLE If gears are allowed to oper ate with an adjustment of this kind galling noise and grooving of teeth will result To obtain correct contact move pinion away from bevel gear to raise contact area to proper location Correct backlash of 006 to 012 may be obtained by moving bevel gear toward pinion Fig 9 A 15847 A CONTACT ADJUSTMENT BACK LASH CORRECTION wise contact and move contact toward heel of tooth Correct backlash of 006 to 012 can be obtained by moving pinion toward bevel gear Fig 10 A SHORT HEEL CONTACT IS NOT DE SIRABLE If gears are allowed to ope
42. blies having as much as 005 end play cannot be moved enough to show on the indicator until the bearing has been worked up and away from the cup CAUTION Bearings must be absolutely clean Preload the pinon bearings by replacing the spacer between the pinon bearings with one smaller to the extent of the amount of the end play plus 002 for the loading For example should there be 005 end play as indicated in the sketch in the assembly replace the spacer with one 007 smaller Do not depend upon the spacers to be right according to number but check each and every one with an accurate micrometer Before reassembling the bear ings to the pinion shaft they should be dipped in rear axle lubricant Propeller shaft flange nut must be pulled down securely to assure tight bearings A wrench with 30 of leverage should be used In order to determine if insufficient or excessive preload has been applied make the following test 1 Place assembly in vise with jaws clamp ing together on the flange of the pinion bearing cage and with assembly in a hori zontal position 2 Grasp the propeller shaft flange with one hand and attempt to turn 3 If the pinion turns freely assembly is too loose If pinion cannot be turned assem bly is too tight 4 The ideal condition is to secure a firm drag when turning the pinion cage by hand After proper bearingfit has been obtained place pinion bearing cage shims approximately
43. d Cage The pinionand bearings are installed in the pinion cage witha pre load secured by following the instructions under Pinion Bearing Pre Load Sec A The pre load in controlled by proper selection of spacers orcombination of spacers located between the outer pinion bearing and bearing seat on the pinion shaft Fig 1 These spacers are ground to close tolerances and are available in graduated thicknesses Thicker spacers decrease bearing pre load and thinner spacer increase bearing pre load For correct procedure see pinion bearing adjustment for correct pre load Sec A When installing the pinion cage assembly in the differential carrier be sure that the oil passage holes in the carrier housing gasket shim pack and pinion bearing cage are aligned When the original gears are being reinstalled use the original shim pack plus a new gasket under the pinion cage Hypoid Ring Gear and Cross Shaft The hypoid ring gear is assembled on the cross shaft by pressing the gear firmly against the cross shaft shoulder Fig 2 To facilitate 010 MIN CLEARANCE ME WHEN Paii HYPOID GEAR E IS_PRESSED N AGAINST gt WEM TS SEAT e HYPOID GEAR ae QUERN 15832 Fig 2 Pressing hypoid gear on cross shaft installation the gear may be heated to 200 to 2509 F Be sure the key is in line with the key slot in the gear before pressing the gear into place The fast speed pinion located betwe
44. e on the pinion by a staking operation Ihe staking operation is accomplished through the use of a hydraulic or screw press applying 18 to 20 tons pressure on the special staking tool as illustrated in Fig 17 The re sult will be uniformly spaced ball indentations that securely lock the pinion bearing to the shaft Differential Ring Gear Rivet Removal If necessary to remove hypoid ring gear or herringbone gear rivets drill the rivet heads from the gear side using adrill slightly larger than the rivet itself Use a punch for the re moval of the remaining portion of the rivet See Fig 18 Knocking off or busting rivets is a dan gerous practice both from the standpoint of personal safety and because such practice may cause distortion to the gear carriers or gears and will elongate the rivet holes Rivet Pressures Proper installation of differential ring gear rivets demands that sufficient pressure be applied to the rivets to expand them and cause them to completelyfill the holes in which they are installed Riveting should be done with COLD rivets Hot rivets will shrink when cool leaving s space andinviting shearing upon the application of torque Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 8 L LINE MOTOR TRUCK SERVICE MANUAL Rivet head Drill bit Ring gear Differential case A 22831 Fig 18 Drill rivet head and punch out rivet as shown
45. e two parts Differential Adjustment The differential assembly is installed in the carrier with the helical gears located to provide approximately 1 16 clearance between the helical gear sides and shift collar faces in both the fast and slow speed positions Move the differential assembly from side to side to obtain this adjustmentby turning on the adjust ing nuts Using dial indicator at the side face of one of the helical gears adjust to no end play 000 end play in the differential bearings Rotate assembly several times to assure normal bear ing contact Tighten adjusting nuts one notch each from 000 end play to secure the correct differential bearing pre load With the dial indicator contacting the side face of the helical gear check for runout If runout exceeds 008 remove differential and check for cause L LINE MOTOR TRUCK SERVICE MANUAL Lubrication l Before starting new truck and after over haul remove pipe plug at pinion cage and insert one pint of specified lubricant 2 Fillaxle housing tocorrectlevel with spec ified lubricant Capacity is 18 1 2 quarts 37 lbs 3 Jack up BOTH rear wheels and operate vehicle in high transmission gear at ap proximately 25 miles per hour for five minutes to assure proper lubrication of all parts before the unit is put into service Both wheels should rotate atapproximately the same speed while the vehicle is jacked up Do not allow one wheel to race faster
46. ed under tension or in a loaded state before gear shift can be accomplished This is provided for bya reversible electric motor which drives a power screw which in turn actuates a drive nut in either direction Trunnions on either side of the drive nut engage slots in the spring lever Movement of the lever in either direc tion energizes the spring which performs the shifting movement The control of the electric shift unit is by means of a two way switchlocated onthe trans mission gear shift lever Figs 2 3 and 4 Moving control button up or down causes motor at axle shift unit to rotate in either direction A limit switch located in the electric shift unit PRINTED IN UNITED STATES OF AMERICA Eo A Boot Control button Switch receptacle E part of wire MS harness Two way switch lt 3 A 22894 Fig 2 Electric Shift Unit Two Way Control Switch Figs 3 and 6 opens the circuit and stops the motor when the shifting spring is fully ener gized Any time thereafter the shift is com pleted by the energy of the spring when torque is momentarily released from the differential gears either by releasing the clutch or closing the throttle A two speed adapter electrically operated is located at the speedometer and is wired in series with the ignition switch Figs 2 3 and 5 The balance of the electrical circuit is also wired in series with the ignition switch thereby preventing any clo
47. ed in cage assemble the pinion and inner bearing cone and roller assembly in place using the proper spacer to space the pinion bearings Next assemble the outer pin ion bearing cone and rollers spacer compan ion flange washer and nut Pinion gear A LA M NE j ee d Indicator N SS v N X a Zee A NS Jud Pe B Retainer Ay 1 M a O d Q 1s e sS Pinion bearing O de cage Mounting of i indicator dm ae A 23437 Propeller shaft flange Fig 16 Fig 16 shows method of attaching dial indicator when adjusting bearing pre load This method can be used when press equipment is not available NOTE Do not install pinion bearing oil sealuntil all adjustments have been completed Then check bearing fit to see that bearings have no end movement with flange nut drawn up tight To secure this fit proper spacer must be found by trial as follows 1 Place assembly in vise in position shown 2 Mount indicator on propeller shaft flange with indicator finger resting on upper face of cage See A Fig 16 3 With the tips of the fingers grasp the bear ing retainer and work bearings up against the back face of pinion See B Fig 16 4 With the bearings held firmly against the pinion move the cage up and down ob serving the indicator reading It is im possible to accurately determine the end play unless the bearing is worked loose and up against the pinion Assem
48. en the hypoid ring gear and splined teeth on the cross shaft should have an end play of at least 010 Normal end play will be from 015 minimum to 030 maximum The slow speed pinion end play must also check to a minimum of 010 The shift collar is installed over the springs and poppets with the longer splines on the in side diameter of the collar toward the hypoid ring gear The cross shaftbearing pre load is meas ured by wrapping wire around the slow speed pinion and pulling with a scale to a reading of approximately 8 pounds rotating torque not starting torque Fig 3 To obtain correct pre load add or remove shims at shim pack under bearing cage on cross shaft end opposite ring gear Use origi nalshim packs plus a new gasket when rein stalling original gears NION lla lt a wSLOW SPEED PI w a GEAR ROTATES OF AuT E RA Po COLLAR IN SLOW SPEED POSITION n HEPA l 5835 Fig 3 Checking cross shaft pre load Gear Tooth Impression and Lash Whenthe hypoid gear sethas been renewed adjust gear back lash with dial indicator and adjust to obtain 006 to 012 lash Movement of the gears is controlled as follows 1 To move pinion toward ring gear remove shims from pack under pinion cage 2 To move pinion away from ring gear add shims to pack under pinion cage 3 To move ring gear away from pinion re move shims from pack under cross shaft bearing cage side opposi
49. ential lubricators aa ee ee A ee bx x 8 4 Ww Y aque Ru s Herringbone gear adjustment TTE ERA AA Herringbone gear shaft cross shaft o oooococooooo o ooroo hh tn Hypoid pinion shaft and adjustment CEA AAA es ee Sectional view Tm ITI TT E ENEE n HH IN NY IN OW SINGLE REDUCTION AXLE TIMKEN DOSC IPO nu iw bue c 4e Kk e UR SS ESOS OH Ow Oe 9 8 ODS NERD AAA amp amp 2 x Differential carrier bearing pre load oo o eee A E Differential disassembly s 2 06 bo POS WSS o3 9 AAA AA A Gear adjustment suo ch eH ow Xo dels Wow REN AEDES how oS o 9c 9 de 9S e 9 ELUBTICALON s e dr aemp IAEA TIT I AAA M Pinion bearing Pre l 0dd s 446 3 0 0 9 X 4 4 MES OSE AAA Sectonal VIEW idu oe EEE 3 9 X9 AAA op Ade 9 koe Ge Ee OE CJ e Ov ded ESS Thrust block installation TERESA AAA AAA SECTION E DOUBLE REDUCTION TWO SPEED TIMKEN DESCIIPION ow SK RE ES sx o 3 9 0 ee ee ee AAA A oe oe Differential adjustment a a E ee ee CAER ai Electric two speed shift EURASIA ee Hypoid pinion and cage o TETERA SETE us LubricalOn esesta ne kEi rr Ure C9 Ut i amp Co ida ty tN ob CO Ww IA Re PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AXLE REAR a L LINE MOTOR TRUCK SERVICE MANUAL SECTION F Page DOUBLE REDUCTION TIMKEN Descriptio
50. er 358 16 Differential side bearing 34 17 Adjusting nut differential 35 18 Axle shaft 36 PRINTED IN UNITED STATES OF AMERICA Pinion bearing cage Slinger Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section D Page 2 L LINE MOTOR TRUCK SERVICE MANUAL TIMKEN SINGLE REDUCTION AXLES Description The Timken Single Reduction Rear Axle R 100 is a full floating hypoid type final drive assembled in a one piece axle housing The differential used in the R 100 Timken Single Reduction Axle is of four pinion type with thrust washers used between the pinions and case The pinions contain bushings which can be renewed when necessary Thrust wash ers are also used between the side gears and case The two halves of the differential case are machined as a complete assembly and must be replaced as such Removal of Differential Carrier Hypoid To remove the differential carrier assem bly remove plug from bottom of axle housing and drain out the lubricant Disconnect the propeller shaft atfront end of pinion shaft Be sureto replace the universal joint trunnions on their respective journals and hold them in place with a short loop of wire until ready to reassemble Remove axle shafts and differ ential carrier to housing capscrews or stud nuts on heavy duty axles and take outcarrier When removing the differential from the axle housing it will be necessary to utilize the two pull
51. er screws to loosen the differential carrier as shown in Fig 2 The differential thrust block screw shown in Figs 3 amp 4 must be removed before the dif ferential can be removed from the carrier Differential The differentialassembly of this axle con sists of four nine tooth pinions mounted on a spider and two 16 tooth side gears all assem bled into the differential case one half being flanged to mount the hypoid ring gear Hardened steelthrust washers areinstalled between the side gears and the case and between the pinions and the case The differential case is held together by twelve bolts eight of which are longerthan the remaining four Differential Disassembly Mark each half of the differential case before teardown so tnat they can be reassem bled in the original position Wash and inspect all parts and replace any which are at all questionable Oil all parts withgear oil before reassembly Use new lockwashers when re assembling L4 Ah eio Fig 2 Loosen lock nuts on two puller screws provided and turn puller screws down into car rier It may be necessary to break carrier loose from housing by striking the carrier with a heavy soft hammer lead or leather ng screw q t A A A TAN i E Tos eS M A 4 Fig 3 Place differential carrier in suitable holding fixture or overhaul stand and loosen the lock nut on the drive gear thrust block ad justing screw Remove thrus
52. hanism is lubricated and sealed for life but the two shaft ends should occasionally receive a small amount of light oil at the oil wick cups Axle Shift Unit This unit shifts the axle into high or low range Fig 6 shows the axle shift unit in the high range of the axle In this position wire b Fig 3 carries current to one field of the motor 6 See Fig 20 for Part Identification so that the armature and drive screw 20 turn ina clockwise direction and move the nut down When the nut has traveled a sufficient distance to wind the spring 23 a contact bumper on the nut breaks an electrical connection on the automatic switch 17 so that the motor is no longer energized andthe armature stops rotat ing To make sure that the nut cannot travel back onthe screw dueto vibration a ball screw detent spring Fig 12 mounted on the cover 26 holds the nut at the end of its travel on the screw The nut moves thespring winding lever 24 down which pivoting on the pin 21 winds the torsion spring 23 for high Thus an in creased load is put on the spring and in this position the axle is ready to snap into the high Speed ratio as soon as the load on the axle gears is relieved The torsion spring is assembled in the unit so that it is under 45 to 65 pounds pressure depending on the size of the axle When the spring winding lever is moved sothat thespring is wound the pressure Lever assembly Limit switch Trunnion
53. he lugs in the step plate straddle the bearing staking in dentations on the smaller axles 2 Install step plate and bracket as shown in Fig 5 CAUTION Be sure lugs on step plate straddle the bearing staking indenta tions 3 Mount assembled SE 1065 gauge in bearing bores of carrier 4 Take micrometer reading to check point of pinion Add 400 thickness of step plate to reading Write down reading 5 Locate specified cone center specification for particular model on chart Write down specified figures 6 Locate on pinion the etched marking which indicates variation from zero cone center If a minus figure subtract from specified cone center and if a plus figure add to specified cone center Results of calcula lion give corrected cone center 7 Comparison of corrected cone center 6 with actual measurement 4 indicates amount of change necessary for pinion position 8 Install ring gear and carrier in position 9 Adjust backlash according to marking on ring gear See following page Example of Mathematics involved Truck model to be L 110 a Micrometer reading add 400 for step plate 3 4400 b Specified cone center on ds ME 0 5 3 400 c Pinion marked 5 005 d Subtraction b c gives corrected cone center 2 995 e Subtract corrected cone center d from actual measurement a 045 f It is necessary to move 0451 pinion IN mea 3 3 g
54. hypoid axles is an important factor in obtaining long gear life and satisfactory drive unit service Past experi ence proves that a large portion of service problems can be traced to using incorrect or lubricant of poor quality In the selection of Hypoid Lubricants it is advisable to consider using products of unques tionable quality Because of the higher unit pressures and sliding tooth characteristics o hypoid gearing the lubricant must have properties which en able it to withstand these actions It is important that the axle hypoid gearing receive initial lubrication after overhaul or when a vehicle has been standing in storage and BEFORE THE AXLE IS SUBJECTED TO HEAVY LOADS Good practice is to check the lubricant level in the axle housing then jack UP BOTH rear wheels and operate the vehicle in high transmission gear at approximately 25 miles per hour for five minutes This will as sure thorough lubrication of the gearing before the unit is placed into service Do not allow one wheel to race faster than the opposite wheel Where the axle pinion cage is provided with a plug at the pinion cage insert one pint of lubricant to provide initial lubrication for the pinion bearings NOTE When reassembling the differential gears thrust washers cross sha t spur gears and bearings lubricate the wearing sur aces with a light coat of the specified axle lubricant This will help provide initial lubrication Use a hy
55. ial carrier mounting capscrew 35 Power divider to differential carrier mounting gasket 36 Differential carrier 37 Bevel ring gear 38 Differential lubricator 39 Differential lubricator retaining capscrew 40 Differential carrier bearing adjuster 41 Differential carrier mounting capscrew Rear rear axle drive shaft outer bearing cover assembly flange nut and thrust washer are identical with the units on outer end of mainshaft A differential lock is available for the power divider This locking arrangement is used to lock both the front rear and rear rear axles together and is generally used when the vehicle is operating in mud snow or off the highway 42 Differential carrier to axle housing mount ing gasket 43 Axle shaft 44 Differential carrier bearing 45 Adjuster lock 46 Differential case bolt and nut 47 Bevel ring gear rivet 48 Differential case flange half 49 Differential spider 50 Differential spider washer 51 Differential spider pinion gear 52 Differential case plain half 53 Differential side gear thrust washer 54 Differential side gear 55 Axle torque arm 56 Axle housing 57 Rear rear axle drive flange 58 Rear helical and side gear thrust washer 59 Rear helical and side gear 60 Breather 61 Differential case male 62 Differential spider 63 Differential case female 64 Rear rear axle helical drive gear 65 Differential case bolts
56. ifferential assembly and remove support case thrust washer Take out differential case bolt lockwire and remove bolts Note short bolts be tween spider arms Lift off right hand differential case Pick up long hub side gear right hand and slip off thrust washer Note chamfered side of washer against back face of gear Pull out spider and differential side pin ions noting thrust washers behind pinions Slip washers and pinions off spider arms Take out short hub side gear left hand and remove thrust washer Note cham fered side of washer against back face of gear 23 Remove differential bearing cones by striking inner race on alternate sides through holes provided in the supportcase 24 In reassembling the pinion use SE 1065 pinion setting gauge in adjusting matched sets of pinions and ring gears to proper cone settings Theoretical cone centers for various axles are found under Specifi cations Rear Axle Section REASSEMBLY IMPORTANT Assembling Differential Unit Lubricate both sides of all thrust washers well Chamfered sides of washers must be against back face of side gears Lubricate spider arms side pinion bores and side gear hubs Draw bolts tight with long handled wrench and securely fasten with lockwire Assembling Planetary Unit Before placing thrust washer lubricate both sides well Cover idler pinion pins with lubricant Chamfered teeth on high speed clutch plate must face pinions P
57. il wick cups On the axle shift unit there is an oil filler plug 27 so marked provided in the front cover 26 near the bottom Upon installation the unit should be filled level with lubricant and should be checked every 10 000 miles or 3 months whichever comes first to maintain this level The lubricant used should be SAE 10 motor oil except where temperatures below 0 F will be encountered in which case use 3 parts SAE 10 motor oil to 1 part kerosene This cold weather mixture can safely be used in temper atures up to 32 F To change lubricant remove front cover 26 and drain Whenever front cover is re moved care should be taken not to allow any dirt to enter AXLE UNIT DISASSEMBLY The axle unit Fig 1 is removed from the differential carrier for disassembly and serv icing as follows A A f Y IN INTER ATIONAL BN y Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section H Page 5 Axle shift assembly Shift Swivel fork notch block A 22648 Fig 8 Remove shift housing to carrier stud nuts and lockwashers and lift off shift unit Upon reassembly the swivel block must engage the shift fork notch Bottom terminal Red wire A 22622 Fig 9 Remove lock nuts and two wires from housing In reassembling the long or rod wire goes to the bottom terminal Gasket A 22628 Fig 10
58. isassem bling Direct reversal of the action will be the proper reassembly procedure See Shop Talk No 1 for step by step illustrations on disas sembly Disassembly Remove differential carrier assembly complete from the truck following the same procedure as you would to take out a single or double reduction unit except in this case the two wires on the shift unit must be discon nected For convenience in handling the head may be placed in the end of a clean small drum The opening should be large enough to accept the bevel drive gear and bearing caps Then proceed as follows 1 Remove the two shift housing to carrier stud nuts and lockwashers and pulloff shift unitassembly See section H for electric shift instructions 2 Remove plug washer spring lockwasher and oil distributor capscrew 3 Pull out shift fork shaft after removing shift fork shaft retainer Fig 2 The shift fork may then be slipped from the sliding clutch gear and removed through the back of the differential carrier 4 Slip out sliding clutch gear 5 Mark right hand differential bearing ad juster with punch This is for relocating when reassembling 6 Remove bearing cap bolt lockwires on both right and left hand sides Loosen cap bolts only Take off right hand bearingadjuster lock and cotter pin 7 Remove left hand differential bearing cap adjuster and lock as an assembly to assure 10 11 12 13 12 1
59. lace notches in oil collector drum between bolt holes in bevel gear Draw bolts tight with long handled wrench and secure wire Pinion Shaft Bearing Adjustment Desired bearing tension is obtained by us ing a spacer of the correct thickness between the bearing inner races There are 12 spacers each of different thickness available for this purpose To make the assembly proceed as follows l Place the pinion and bearings in position in the cage using original spacer provid ing the pinion did not have any perceptible end movement before disassembly 2 Then assemble flange washer and flange Tighten retaining nut securely There should be no perceptible end play and bear ing should roll freely If correction is to be made select proper size spacer to ob tain desired fit Assembling Differential Carrier Unit Lubricate all bearings as they are assem bled in carrier After adjusting gear be sure cap bolts are tight Wire bolts securely in cluding capscrews in adjuster lock Pinion Bearing Pre Load Follow instructions given in Hypoid Rear Axle Section A page 6 Differential Carrier Bearing Pre Load The correct procedure for securing the specified carrier bearing pre load as listed in the Rear Axle Specification for these axles will be found in Section A Hypoid Rear Axles PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL
60. les in the flange will indicate a lack of clearance at this point Y IMA Hi Axle shaft flange A 19632 Fig 21 Push the axle shaft flange back into position against the wheel hub and again strike a sharp blow in the center of the axle shaft flange This will cause the axle shaft to spring away from the wheel hub and allow re moval of the axle shaft without resorting to the use of a pry bar or screwdriver Do not pry between the axle shaft flange and wheel hub To do so is apt to damage the seal as sembly or machined surfaces of the wheel nub or axle shaft flange When reinstalling the axle shafts there must be a slight clearance between the lockwashers and driving flange see Fig 20 Excessive wear on studs dowels or holes in the axle flange will take place when no clearance exists Axle Housing Breather Valve When the rear axle becomes warm a ter a short period of operation a pressure is built inside the axle housing To prevent this pres sure fromforcing lubricant past the rear wheel oil seals and damaging the brake linings a breather valve has been provided The valve is so constructed that warm air may pass out of the axle to relieve built up pressure yet dirt and moisture are prevented from entering The location of the breather valve is shown in Fig 18 inset shows detail of valve The breather valve should be kept open and clean When the vehicle is operated or un improved highway
61. mains constantas long as the gears remain undamaged or the differ ential carrier bearings are not wornexcessive ly The self aligning differential carrier bear ings eliminate the need for adjustment to align the herringbone pinion and herringbone ring gear The heavy duty roller bearings permit Ml N j INTERNATIONAL Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section C Page 3 the differentialcarrier to move sidewise within the bearing race sufficiently to keep both gears in perfect alignment at all times Differential Differential is convential four pinion type with thrust washers back of side gears and pin ions Cases are supported on heavy duty roller bearings Differential Lubricators The double reduction axles have special provisionincorporated to supply oil to the her ringbone pinion shaft bearings as well as the hypoid pinion sha t bearings This is accom plished by scooping lubricant fromoil collector discs mounted on the herringbone gear and the hypoid ring gear The lubricant is picked up from these discs by oil scoops and circulated through special passages to thedifferentialcar rier bearings and the herringbone pinion shaft bearings Fig 2 illustrates the flow of oil and the principal of this means of bearing lubrica tion PRINTED IN UNITED STATES OF AMERICA Lubrication of Hypoid Axles The lubricant used in
62. mbly 11 Withdraw mainshaft all the way Front helical and side gear thrust washer and differential lock where power divider is so equipped can now be removed through pinion bearing sleeve opening PRINTED iN UNITED STATES OF AMERICA 12 Using a suitable puller remove both front and rear mainsha t bearings This com pletes disassembly of mainshaft 13 Remove the nine transfer case cover re tainer screws Carefully remove cover so as not to damage cover or gasket face of transfer case as cover must be removed from front bearing of rear rear axle drive shaft 14 Remove nut at front end of rear rear axle drive shaft The companionflange at rear of shaft should be used to hold shaft while removing nut 15 Remove companion flange retaining nut and flange at rear of rear rear axle drive shaft Remove companion flange with suit able puller 16 Remove the four bearing cover retaining capscrews and remove bearing cover 17 Remove bearing at front end of rear rear axle drive shaft using a suitable puller Also remove helical gear retaining washers 18 Tap front end of rear rear axle drive shaft with a soft hammer to remove helical drive gear and spacer This action will also drive the rear bearing out of case so that the shaft may now be lifted out 19 Place rear rear axle drive shaft in vice having soft jaws and pull the rear bearing off the shaft The power divider is now completely disas sembled Place all
63. n T LT so oo t t n TI TENEN 1 Helical gear shaft cross shaft Se a rrr 3 Hypoid pinion and cage ee enn cb widow AA EE E E 3 PMDPICANON 46a oa ao OA AAA aaa iR dd 3 Oil sedal cae ea miss Cao os Ss oe ee Se ee Be oe wee we ee we cee uw a 2 SECTION G TANDEM AXLES Center cross bar and equalizing beam mounting oo o o o TEN 4 Description sa 4 home X 40x 3 3 08 3 33 5 945 E 9 39 3 9 9 9 4 NETO 1 Differential lock T ELE A 2 Disassembly of power divider axle mounted TTC 3 4 Equalizing beam endS 4 4 css css cn 4 5 Legends for sectional view SURE ERA AA 2 Sectional view axle mounted power ouk Tr l Torque rod ends 3 4 EE dO ado aaa TEVE TN 3 4 9d 5 SECTION H ELECTRIC SHIFT Axle shift UNID o serrana naa rrr LIS Axle unit disassembly 4 4 995v ox eee X E VOX ooo 9x o8 ROS 9o Wow do Rete T 4 7 Description AE as a T l 2 LUDTICAMON sisi sarria wy wow ds Kx ow Pw 9 m P X X uw s 9429 4 b d 4 4 Parts identification liSt serio Tam 8 Service and trouble shooting je d TUTTI 3 4 oblt ng 1B8SIrucHODS xe 4 04 akaa ARANA ENE ee we we 7 Speedometer adapter ooo oooo oo oo ee 3509 3098 3 E 909 0972 ee Te 2 Wiring System wow ee oe ee ee Se ee TETAS Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Specifications
64. nd oil filler plug Fig 1 and fill to level of plug hole with spec ified lubricant Capacity for the R 100 axle is 30 pints 30 lbs Capacity of the L 100 axle is 23 pints 23 lbs 2 Jack up BOTH rear wheels and operate vehicle in high transmission gear at ap proximately 25 miles per hour for five minutes to assure proper lubrication of all parts before the unit is put into service Both wheels should rotate atapproximately the same speed while the vehicle is jacked up Do not allow one wheel to race faster than the opposite wheel To do so might cause serious damage to the differential spider and gears Use SCL EP gear oil or a multi purpose gear lubricant suitable for hypoid axles and supplied by a reputable refinery SAE 90 for cold climate and SAE 140 for warm climate Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only AXLE REAR L LINE MOTOR TRUCK SERVICE MANUAL Mi er age TIMKEN 300 SERIES AXLES du 3 FAST SPEED SLOW SPEED HELICAL GEAR HELICAL GEAR NIZA DIFFERENTIAL ASSEMBLY FAST SPEED wae FREE ROLLING WHEN COLLAR A ENGAGES SLOW SPEED PINION 9 HYPOID GEAR pu E 0x 3 HYPOID PINION S SPACER SELECTION OF PROPER SPACER GIVES 2 SLOW DESIRED PINION BEARING W SPEED PINION PRE LOAD CROSS SHAFT ASSEMBLY SHIFT COLLAR SLIDES ON SPLINED PORTION OF SHAFT ENGAGING DESIRED PINION SPLINES ON FREE ROLLING S
65. nding on the test light to ground Turn on ignition switch or accessory switch in the case of a diesel and the light should show If it fails to light at this point there is a poor connection or broken wire between the ignition switch and circuit breaker Next connect test light to Point a on the circuit breaker Fig 3 and again the light should show If it fails to show im mediately watch the light carefully and listen to the circuit breaker for a minute to see if it is flashing off and on The light should stay on continuously at this point If it flashes off and on or you hear the breaker clicking it indicates that too much current is flowing and the circuit breaker is opening This is due either to a short circuit or the motor in the shift unit not being free to run To deter mine which ofthese it is remove the two wires b and c from the axle shift unitand recheck If the light still flashes off and on or you still hear the breaker clicking it is due to a short in the harness but if the light now stays on continuously the trouble is in the shaft unit If there is no light at allat this point and the circuit breaker cannot be heard clicking disconnect the green wire from terminal a Fig 3 and again clip the test light to terminal a post on the circuit breaker If the light fails to show here and did show on terminal d the circuit breaker is bad and should be re placed If the test light glowed normally at
66. nicn setting at time of overhaul or when replacing differential bearings and every effort must be made to be sure the final setting results in best possible tooth contact Note that the pinion center line E F is offset from the ring gear center line C D Hypoid ring gear Cone Y center ee P ud j B O Hypoid pinion Fig Illustration shows location of pinion in relation to center line of ring gear Center line of pinion is below center line of ring gear A 22828 NOTE When adding to or replacing lu bricant in a rear axle having hypoid gears use only hypoid lubricants See under Lubrica tion on page 9 PRINTED IN UNITED STATES OF AMERICA REAR AXLE HYPOID GEAR REPLACEMENT AND ADJUSTMENT Hypoid Gear Tooth Contact All Models The proper adjustment of hypoid gears in assembly is a vital factor in obtaining quiet and durable gears and the same methods of adjust ment applies to both straight spiral bevel and to hypoid type gears There are two distinct considerations in obtaining the proper tooth contact cone center and backlash Hypoid as well as bevel and spur gears are cut with a predetermined amount of backlash The backlash usually varies from 004 to 005 on small gears and increases on large gears Generally the gears are machined to run flush with each other at the outer end heel or large end of the tooth and gears should be set according to their theoretical
67. nspections indicate a run out of 004 a new differential case should be installed When assembling drive gear on face of flange make sure each rivet is tight The best results are obtained if a press is used to install rivets Follow the instructions outlined under Rivet Pressures on page 8 Section A Hypoid Pinion Shaft and Adjustment Adjustable hypoid pinion bearings are assembled to pinion shaft and retained by universal joint flange and nut on forward end of pinion shaft A spacer available inseveral thicknesses is used to maintain correct distance between front and rear bearings and to secure the pin ion bearings pre loadas indicated in Rear Axle Specifications The pinion cage is mounted in the conventional manner and the correct cone center adjustment is secured by means of a Shim pack under pinion cage flange See SE 1065 Pinion Setting Gauge Section A page 2 L LINE MOTOR TRUCK SERVICE MANUAL AMA IMPORTANT Hypoid drive pinion oil seals must be soft and pliable before being in stalled if the seals have become dried out and hard while in stock use kerosene and work it in thoroughly When seal has become soft and pliable dip it in hot oil and work this oil in thoroughly Pinion Bearing Lubrication NOTE When reassembling differential to axle housing or new and dry differential is used from stock be sure to inject about one pint of differential lubricant into the pinion bearing housing
68. ntact is accomplished by means of oiled red lead applied lightly to the bevel gear teeth Fig 6 When the pinion is rotated the red lead is squeezed away by the contact of the teeth leaving bare areas the exact size shape and location of the contacts COAT WITH RED LEAD y EP BEVEL GEAR Fig 6 Fig 7 Sharper impressions may be obtained by applying a small amount of resistance to the gear witha flat steel bar and using a wrench to rotate the pinion When making adjustments check the drive side of the bevel gear teeth Coast side contact should be automatically corrected when drive side contact is correct As a rule coating about twelve teeth is suffi cient for checking purposes With adjustments properly made the correct tooth contact shown in Fig 7 will be secured The area of contact starts near the toe of the gear and extends about 80 per cent of the tooth length This adjustment results in a quiet running gear and pinion set which because the load is distributed over the teeth within the proper area will deliver all the long service built into it Figs 8 to 11 illustrate method of adjust ment in securing the proper gear tooth contact Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 4 L LINE MOTOR TRUCK SERVICE MANUAL CONTACT ADJUSTMENT B BACK LASH CORRECTION Contact adjustmeni Back lash correction gt en LN Re a High n
69. o ERE AIR 28 to 33 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only
70. o deep in ring gear Worm section of ring gear Ring gear Overlap Correct Incorrect A 19693 Fig 12 Fig 12 illustrates worn condition of gear teeth and overlapping condition When installing new gears check gear lash with dial indicator Fig 13 and adjust to obtain amount of backlash marked on ring gear as follows l Set pinion according to procedure outlined under SE 1065 Pinion Setting Gauge 2 To move ring gear tighten or loosen differential bearing adjusting nuts as re quired 3 After correct gear lash is secured check and adjust as necessary to obtain the correct tooth contact See Gear Adjust ment for correct tooth contact PRINTED IN UNITED STATES OF AMERICA A 22508 Fig 13 Checking gear lash Adjust Differential Bearing Pre Load Using dial indicators at side of each bear ing cap Fig 14 adjust to obtain bearing pre load as follows l Loosen adjusting nuts only enoughto notice end play on indicators 2 Tighten adjusting nuts only enough to obtain 000 end play reading on indicators Note While gear is held in 000 end play and before loading bearings check gear for runout If runout exceeds 008 re move differential and check for cause Dial indicators Adjusting wrench DB d A 22496 Fig 14 Adjusting differential bearing pre load Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section A Page 6 3 Tighten BOTH adj
71. on and a wide faced helical gear andhelical pinionfor the second reduction A range of gear ratios is available to meet all operating requirements See Specifi cations Axle Housing The axle housings in both axles are simi lar in design although the U 200 P axle hous ing has larger sections to produce its greater load carrying capacity Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section F Page 2 L LINE MOTOR TRUCK SERVICE MANUAL Differential The differential assembly of this axle con sists of four 9 tooth pinions mounted on a spi der and two l6 tooth side gears all assembled into the differential case both halves of which are identical Hardened steel thrust washers are in stalled between the side gears and the case and between the pinions and the case The large helicalgear is mounted betweenthe differential case halves and the assembly is held together by twelve rivets The differential assembly is mounted in tapered roller bearings Oil Seals The rear wheel outer oil seal is illus trated in Fig 2 This is the latest type oil seal assembly and when installing this seal be sure to cement the new cork gasket tothe inner flange of the new wiper ring Gasket Gasket Wheel hub C TS SS SS SY A MS ea A retainer 7 ZZ NN f fi UR YN i DANN Y Seal wiper Cork gasket cemented to seal wiper A 16014 Fig 2 Illustrates sectional view of se
72. owosa dew EH X w do ox OR E camas 3 Cab door glass window channel amp 5 5 5554 FA DESERT E DED sida ss 3 4 5 Cab rear window glass ee ee ee eee se ee m 5 6 Panel body rear door glass 44686 eed nie 6 WinasMeldS 5 5 cue a OG as RO 3 E9909 309 V OV WO 9180 HO RA 6 7 8 9 Cab door vent glass WINDOW aserat esasi trs nts 4E RC R C CCTRCUE AAA 9 10 Gab door latch and remote control a 6 66K 669 c9 EO X EORUE AO do ADEN OSE HE I Ll I2 13 Removal of outside door handle misa visos rca 13 Installation of outside door handle ae sss osere 9 is rod 13 Lock cylinders and REVS auo o9 THEE DE 799 DK OCR ROLE EUR e EE ES 13 14 Ignition SWIC v ew wow EOE PURE RE udo X wm RUN Ec o OR RC PS OOH 14 bon s rrr 14 Cab door removals a iu bees tars o3 4 sra SG CEP 5 40 4 EM HERS x 14 15 COW ventil lOf soran stietst ern rE ES o Qd Ur AAA 15 16 Deut AJUSTE va oko EAS DAA ede o OR RO CES WOW qoc ce o rd 16 17 Gab WAOUntINGS gt 2 5407 wu a wu oo AEREA OU I Un x ROC SEHD SD 17 18 19 20 Hood assembly 4 coo o EHO 4 e oy RR v od 20 21 Fender and radiator grille 5 4 oe eo ces cs an ee ee ee 214 22 23 24 Body MOURUINGS ao he REED ERED ERR EEE Ew OED EW EES A 24 Furth Wheel Mounting sera AAA HE EDA AAA AAA 25 26 Panel and pick up body mountingS oo o ooooooo ooo oo so os o o o 21 Windshield Wipe Rawo 3 o4 4 9 9 ENG Euer ud X
73. poid gear lubricant available as ElcoGear Safety 28 or its equivalent A num ber of hypoid lubricants are prepared by repu table companies which contain Elco additive concentrates Viscosity ofthe hypoid lubricant shouldbe SAE 90 Whenhighatmospherictem peratures fabove 100 F prevail SAE 140 may be used Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section D Page 1 SINGLE REDUCTION AXLE TIMKEN 100 SERIES AXLES 39 gt T 1 H k MM 2 3 y 4 n 5 ptg 6 a D en JI L 1 wer EN A 1963 Adjusting nut lock Differential bearing cap Side gear thrust washer Side gear Pinion thrust washer Pinion bushing Differential spider Pinion gear Bevel drive gear Rivet Differential pan bolt long Differential case Differential case bolt short Thrust block adjusting screw Lock nut Thrust block Differential carrier Fig Single Reduction Timken 100 Series Axle 1 Pinion shaft nut 19 2 Pinion shaft nut washer 20 3 Companion flange or yoke 2l 4 Oil seal 26 5 Thrust washer 234 6 Pinion bearing outer 24 7 Pinion bearing spacers gt 25 8 Cover gasket 26 9 Bearing cover 2T 10 Pinion bearing cage shims 28 11 Pinion bearing inner 29 12 Pinion 30 13 Lubricant filler plug 315 14 Pinion radial bearing 32 15 Breath
74. point a next remove the two wires b and c from the axle shift unit and connect a test light wire to one of these wires and the other test light wire to ground The red shift unit wire should light the light only in high gear or up position on the gear shift lever switch and the black wire should light the light only in the low gear or down position of the gear shift lever switch If the light fails to glow in either of the above tests it indicates a broken circuit in the har ness or gear shift lever switch If both wires light the test light in one position of the gear shift lever switch it indicates a short circuit in the harness or gear shift lever switch Next connect the test light to the speedom eter adapter terminal c and ground Here Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section H Page 4 the light should glow in the low gear or down position of the gear shift lever switch only If it fails to glow it indicates a broken circuit in the harness or gear shift lever switch These checks above will quickly locate the trouble When checking the harness for short or open circuits watch for broken insulation and do not overlook the gear shift lever switch which can best be tested by substituting a new one in its place If the vehicle shifts normally but the speedometer adapter fails to operate properly make the above check with the test light to see if itis getting current in the lo
75. power divider in a transmission stand or other suitable fixture and remove the four pinion bearing cage mounting cap screws and remove pinion shaft cover 3 Remove self locking setscrew in the trans fer case to release pinion bearing sleeve 4 Remove pinion shaft outer bearing nut and using a soft hammer tap end of shaft to release pinion bearing sleeve and bearing from housing Withdraw pinion shaft as sembly from transfer case Complete dis assembly of shaft by removing inner pinion bearing spacer front axle helical drive gear and pinion bearing 5 Remove pinion bearing cage from transfer case 6 Remove mainshaft bearing retainer nut inner end 7 Remove companion flange mounting nut and using a suitable puller remove com panion flange and slinger assembly 8 Remove four bearing cover capscrews and lift off bearing cover 9 Using a bronze bar drive inner end of main shaft until shaft passes through rear helical and side gear and thrust washer This gear and washer can now be removed through pinion bearing sleeve opening in transfer case 10 Continue pushing mainshaft toward front of transfer case until differential case as sembly and thrust washers are free of shaft Differential case will also pass through pinion bearing sleeve opening in case Mark differential case halves so original assembly can be duplicated Keep differential spider thrust washers with differential case to as sure correct reasse
76. r lubrication of all parts before the unit is put into service Both wheels should rotate atapproximately the same speed while the vehicle is jacked up Do not allow one wheel to race faster than the opposite wheel To do so might cause serious damage to the differential spider and gears Use SCL EP gear oil or a multi purpose gear lubricant suitable for hypoid axles and supplied by a reputable refinery SAE 90 for cold climate and SAE 140 for warm climate Hypoid Pinion and Cage The pinion and bearings are installed in the pinion cage with a pre load as indicated in Rear Axle Specifications for these axles The pre load is controlled by proper selection of spacers or combination of spacers located between the outer pinion bearing and bearing seat on the pinion shaft These spacers are ground to close tolerances and are available in graduated thicknesses Thicker spacers de crease bearing pre load and thinner spacers increase bearing pre load For correct pro cedure see Pinion Bearing Adjustment for correct pre load Section A page 6 When installing the pinion cage assembly in the differential carrier be sure that the oil passage holes in the carrier housing gasket shim pack and pinion bearing cage are aligned When the original gears are being reinstalled use the original shim pack plus a new gasket under the pinion cage Helical Gear Shaft Cross Shaft The helical gear or cross shaft is mounted at right angles to
77. rate with an adjustment of this kind chipping excessive wear and noise will result To obtain correct contact move bevel gear toward pinion to increase the lengthwise contact and move contact toward toe Cor rect backlash of 006 to 012 can be ob tained by moving pinion away from bevel gear Several adjustments of both pinion and gear may be necessary before correct contact and backlash are secured Fig A 15849 A CONTACT ADJUSTMENT BACK LASH CORRECTION A 15850 Donated by John amp Susan Hansen For Personal Use Only YAN IN Y L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section A Page 5 Gear Adjustment for Lash Generally if original gears are being rein stalled red leading of teeth will not indicate the same contact as newgears and can be mis leading Gears that have been in service for long periods form running contacts dueto wear of teeth therefore the original shim pack should be maintained to check gear lash Gear lash when using original gears can be reduced only to a point of smooth rotation of gears If the gear lash is in excess of maximum tolerance as stated under Gear Adjustment the lash may be reduced only in the amount that will avoid overlap of the worn tooth section Fig 12 Rotate the gears and check for smooth or rough operation If a slight overlap as illustrated Fig 12 takes place at the worn tooth section rotation will be rough Pinion to
78. ronze bushings are burnished by means of a stud ball which when being pressedthrough the pinion bushings compresses the bushing metal giving a denser surface and tighter fit in the pinion The burnishing operation also locks the bushings in place in the pinion since some of the bushing metal is compressed into the locking groove located on the inside bore of the pinion The correct size ball should be ap proximately 005 larger than the spider trun nion Do not attempt to ream the spider pinion bushings Pinion The pinion cage can easily be withdrawn rom the differential carrier with the use of puller screws provided PRINTED IN UNITED STATES OF AMERICA Press burnishing ball through bushing A 19691 Fig 6 Use bar to press burnishing ball through bushing The correct size ball should be approximately 005 larger than the differ ential spider trunnion Remove the pinion shaft from the pinion cage on a press Remove the inner pinion bearing with a suitable puller The inner radial bearing retainer is removed after removal of the retainer screw Pinion Bearing Pre Load When the pinion shaft bearings bearing spacersand pinioncage have been reassembled Read scale while pinion cage turns Fig 7 Checking pinion bearing pre load using torque method Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section D Page 4 L LINE MOTOR TRUCK SERVICE MANUAL
79. s or in ice and snow it is possible that dirt willbe forced under the valve cap thus rendering the valve ineffective Re move valve occasionally and clean thoroughly in a cleaning solution NOTE Where power divider is mounted on rear axle the breather is mounted on upper side of the power divider PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section A Page 9 Location of breather valve on heavy duty axles lt Sealing washer Marido Rear axle housing breather valve EE 7 HH 22634 Fig 22 Keep breather valves clean and free of obstruction Breathers are usually located in housing as illustrated IMPORTANT Lubrication Of Hypoid Axles The lubricant used in hypoid axles is an important factor in obtaining long gear life and satisfactory drive unit service Past experi ence proves that a large portion of service problems can be traced to using incorrect or lubricant of poor quality In the selection of Hypoid Lubricants it is advisable to consider using products of unques tionable quality Because of the higher unit pressures and sliding tooth characteristics of hypoid gearing the lubricant must have properties which en able it to withstand these actions It is important that the axle hypoid gearing receive initial lubrication after overhaul or when a vehicle has been standing in stor
80. se differential assemblies that are identical in construction except that a spacer or thrust block is used when the unit is installed in a L 110 axle Since the L 110 axle is of semi floating construction a means of taking up the end thrust of the axles and wheels must be pro vided The block serves this purpose The wheel bearings pick up the end play or thrust on the L 120 full floating axles and no thrust block is needed Also the axle shafts in the full floating design are slightly longer than those used in the semi floating design and for this reason the thrust block must be removed when the differential unit is used in the L 120 series vehicle Removal of the thrust block is as follows l Drive cross pin retainer pin from differ ential case so as to clear the cross pin Fig 23 A 23436 Fig 23 Driving retainer pin from differen tial case using a hammer and punch 2 Using punch drive the cross pin out of differential case far enough to remove the thrust blocks Fig 24 Cross pin Retainer pin Fig 24 3 Push cross pin back into position in the differential case Drive retainer pin into position and stake case to secure retainer pins Fig 25 Stake the case to secure retainer pin Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section A Page 11 DO NAM BW Po SINGLE REDUCTION HYPOID AXLE UNIT SHOWN IS MODE
81. se the distance is greater SE 1065 Pinion Setting Gauge The SE 1065 pinion setting gauge is a pre cision gauge designed for use in adjusting differentials to the proper cone setting of the ring gear and pinion It is used only in adjust ment of matched sets of gears A step plate and bracket have been added to the set so that the gauge may be used on all hypoid differen tials with satisfactory results NOTE Be sure to allow for thickness of the step plate 400 when making calculations Fig 5 The use of SE 1065 gauge makes possible the exact duplication of the setting etched on the pinion This results in the best possible setting with a minimum loss of time It is ad visable to check all pinion settings with a paint impression before considering the work com plete By so doing visible proof of the pinion gauge setting accuracy is obtained also long and quiet gear performance is assured Adjustment of differentials is a simple matter with the SE 1065 gauge Briefly it is only necessary to l Install pinion and bearing assembly in differential carrier L LINE MOTOR TRUCK SERVICE MANUAL A WW Bracket screw AH Eum Prove NP io i tr NES ei 3 Ea A Step plate A 22494 Fig 5 Fig 5 shows SE 1065 tool equipment in position on hypoid differential case Make certain that the bearing bores are clean and free of nicks or burns The step plate must be placed on the pinion end so that t
82. sed electrical cir cuits in the system when the truck is idle and the ignition switch is turned to the OFF po sition Speedometer adapter Gear shift lever switch Shift motor A D b Circuit gnition breaker switch Black Green Automatic switch S Red B uS Black A 22525 Fig 3 Electric Shift Circuit Diagram Donated by John amp Susan Hansen For Personal Use Only AXLE REAR Section H Page 2 Speedometer Two way Shifting motor switch assembly adapter a Circuit amp breaker Y Harness assembly N rear Harness assembly front A 22895 Fig 4 Illustration Of Electric Shift Parts The system is further protected by a self resetting circuit breaker which becomes operative when normal current flow continues fora period longer thanis requiredto complete a shift or in case of an overload or direct short Details ofthe various units ofthe Electric Shift their function and the servicing of each follows Theswitch Fig 2 with which the operator controls the axleis located onthe transmission gear shift lever This controlswitch has two positions up and down Three wires are connected to the switch When the selector button of the switch is up the battery wire A Fig 3 is con nectedto wire B Fig 3 leading to one field of the motor in the axle shift unit proper When the button is down the ba
83. t block adjusting screw from carrier This will permit the thrust block to fall into the carrier iRotate gear to Ibring hole in block amp in line with adjusting M SCFeW Thrust block d 19696 Fig Y When replacing thrust block place block on gear and rotate gear to bring block in line with adjusting screw Donated by John amp Susan Hansen For Personal Use Only AXLE REAR L LINE MOTOR TRUCK SERVICE MANUAL n Center punch i k each Pun Press T lt Press bar Rivet cut through B than rivet diameter Ring gear WIN AL AGE e i cu E A 19661 ring Fig 5 If it is necessary to remove the gear from the differential case half carefully center punch each rivet in the center of the rivet formed head as shown Drill through the center of each rivet formed head using a drill slightly larger than the body of the rivet Punch or press rivet out of gear and case half If inspection reveals that the ring gear should be replaced exercise care when remov ing the ring gear rivets Fig 5 shows the correct way to remove the ring gear rivets to avoid damage to tbe differential case The four differential spider pinion gears run on bronze bushings and where they are found to be worn excessively the bushings can be replaced Cut the old bushings out of the pinions and using the special tool shown in Fig 6 installand burnish the new bushings in the pinions B
84. t is necessary to remove the pinion cage assembly Illustrations show details of the checking pro cedure with the carrier removed from the axle housing and the differential gear assembly re moved PRINTED iN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section E Page 3 Check clearance of shift fork collar flat faces in shift collar with feeler gauge Fig 4 The clearance should not be less than 010 minimum on each side of the fork in both the fast and slow speed positions When checking this clearance the shift collar must be flush with the end face of the spur pinion in both fast and slow positions Shims located at the shifting chamber bracket regulate the travel range of the shift rail and fork Add or remove shims to allow the shift collar to seat flush against the spur pinions in both high and low positions Fig 5 amp 6 The electric shift chamber and bracket assem bly must be removed from the carrier in order to remove shims Bracket Spring completes shift Bell crank when engine torque Shift motor is released mounting C SCR UNS NS Lr PDL ZA e 7 MEE A d SUE Lu i inii A y arenes 3171 100 LEO AD ZZZ PES RAR Shifting shaft gt shaft A 22924 of front mounted electric Fig 5 Details Note location of shims for shifting mechanism travel adjustment E
85. te ring gear and add shims of equalthickness to pack under cross shaft bearing cage ring gear side Shims should be transposed in this manner to maintain the established pre load 4 To move ring gear toward pinion remove shims from pack under cross shaft bearing cage ring gear side and add shims of equal thickness to pack under cross shaft bear ing cage side opposite ring gear Shims should be transposed in this manner to maintain the established bearing pre load When correct gear lash is obtained check and adjust as necessary to obtain correct tooth contact using oiled red lead applied lightly to the ring gear teeth Gear tooth impression illustrations are shown in Section A pages 3 and 4 Shift Collar Adjustment The shifting collar serves as the lock be tween the cross shaft and either the high or the low speed spur pinions When engaged with either speed spur pinion the collar must be flush against the spur pinion face Fig 4 The collar is held flushagainst the pinions by three spring loaded poppets located inthe cross shaft and unless there is misadjustment in the loca tion or travelof the shifting fork the collar will seat itself against whichever gear is selected Fig 4 Checking clearance between shift collar 010 MIN EACH SIDE OF SHIFTING FORK and spur pinion Clearance should not be less than 010 To check the travel of the collar when the differential is mounted on the axle housing i
86. the press shown in Fig 2 After the correct pinion bear ing pre load reading has been secured remove outer pinion bearing and pinion bearing cage only The pinion shaft is now ready for install ation Complete assembly of pinion shaft to transfer case by inserting pinion shaft through pinion bearing sleeve opening until sleeve is in correct position Install pinion bearing cage outer pinion bearing thrust washer and nut Do not fail to install pinion bearing sleeve set screw after the cone center and back lash ad justments have been made Use a new bearing cage cover oil seal when completing assembly After the correct pinion bearing pre load has been obtained mount power divider on differ ential carrier The pinion cone center adjust ment may now be made Follow procedure set forth under SE 1065 Pinion Setting Gauge Bear in mind the adjustment of the bevel pinion is controlled by means of a shim pack under the pinion bearing cage at forward side of power divider The differential assembly may now be completed and the bevel ring gear adjusted for back lash as marked on outer rim of ring gear Be sure to obtain a tooth contact pattern as outlined under General Rear Axle Hypoid Pinion and Ring Gear Adjustment Point Im pression Method The differential carrier and power divider assembly is now complete and ready for in stallation in forward rear axle housing Use a new differential carrier mounting gasket Center Cross Bar
87. through the filler plug opening at the side of the carrier This will provide immediate lubrication for the pinion bearings upon placing the unit in operation Herringbone Gear Shaft Cross Shaft The herringbone drive pinion gear shaft is mounted at right angles to the hypoid pinion shaft in the carrier housing This shaftis a one piece steel forging consisting of an integral herringbone gear in the center and an integral flange on one end to which is bolted a hypoid ring gear To remove this shaft it is necessary to remove the differential and herringbone ring gear assembly Then withdraw the hypoid pin ion and cage assembly far enough to clear the hypoid ring gear when being removed Re moval of universal joint flange is unnecessary Remove both bearing covers and using a soft hammer tap ring gear end of shaft until the bearing cup at opposite end of shaft is removed from carrier housing This will permit suffi cient opening to partly pass shaft through until bearing is clear of carrier housing at ring gear end of shaft Tilt ring gear end of shaft to rear and withdraw from carrier The cross shaft bearing covers control the hypoid pinion and ring gear backlash and tooth contact as well as the bearing pre load This is accomplished by means of a shim pack under each bearing cover Herringbone Gear Adjustment Herringbone gears are not adjustable for backlash This clearance is taken into account in the constructionand re
88. ting stud Differential bearing Differential bearing adjuster Oil passage to pinion bearings Pinion bearing cage shims Pinion bearing cage Pinion oil seal retainer Pinion oil seal Slinger Companion flange Thrust washer Propeller shaft companion flange nut Pinion cage mounting capscrew Differential carrier mounting capscrew Pinion bearing cage cork seal Thrust washers Pinion bearing outer Pinion bearing spacer Pinion bearing inner Hypoid pinion straddle mounting Pinion bearing Differential case bolt lockwire Differential case bolt Differential carrier Differential carrier mounting gasket Axle shaft Differential bearing adjuster lock Differential side gear thrust washer Differential case plain half Differential side gear Differential spider pinion Differential spider pinion thrust washer Differential spider Differential case flanged half NTER A VAN Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AXLE REAR Section B Page l So DON O Ut AWN TWO SPEED AXLES SEE SECTION H FOR ELECTRIC SHIFT Hypoid ring gear Oil collector drum Ring gear case Thrust washer Bearing cap stud Bearing cap Carrier bearing Clutch plate Sliding clutch Shift fork Shift fork shaft Clutch plate Sliding clutch Diaphragm seal Gear case bolt Shifter motor stud Fig Two Speed Axle Eaton
89. tion Ifa slight overlap takes place at the worn tooth section rotation will be rough Dial indicator Fig 8 Checking gear lash When installing new gears check gear lash with dialindicator Fig 8 andadjust to obtain 006 to 012 lash as follows 1 To move pinion toward gear remove shims from pack under pinion cage 2 To move pinion away from gear add shims under pinion cage 3 To move gear tightenor loosen differential bearing adjusting nuts as required After correct gear lash is secured check and adjust as necessary to obtain the correct tooth contact See gear Adjustmentfor correct tooth contact Adjust Differential Bearing Pre Load Using dial indicator at back face of ring gear Fig 9 adjust to obtain bearing pre load as follows l Loosen adjusting nut on side opposite gear teeth only enough to notice end play on in dicator 2 Tighten same adjusting nut only enough to obtain 000 end play reading on indicator NOTE While gear is held in 000 end play and beforeloading bearings check gearfor runout If runout exceeds 008 remove differential and check for cause sA Ciis made N at this nut a EX d 5 i Dei y oet CREAN Y s sj vm i o vs EM d R gt ass S E ms P E ya ES y LA gt UE M a f Sari 3 Cu wee x a n a i u 1 y E a A A ai i au 3 j A E Eta 7 o Axe M at e Call A 19695 differential Fig
90. tion List And Illustrations Screw with lockwasher motor cover to housing Elastic stop nut motor to cover Motor cover cable clip Motor support and cover Motor support and cover gasket Electric motor assembly Electric motor grommet Shift motor housing Jam nut automatic outside Fibre washer automatic switch termi nal outside Bushing automatic switch terminal hole in housing Bearing with snap ring Bearing lock nut Bearing cover gasket Bearing cover switch terminal 16 i 18 19 20 m Zee 3s 24 25 26 Ale 20 Screw with lockwasher bearing cover to housing Automatic switch terminal screws base gasket assembly Flat head screw automatic housing inside Elastic stop nut automatic switch termi nals inside Drive screw assembly Spring winding and shift fork actuating lever shaft Shift fork actuating lever assembly Torsion spring Spring winding lever assembly Shift housing cover gasket Shift housing cover 1 8 pipe plug Screw with lockwasher shift housing cover to housing and switch to Donated by John amp Susan Hansen For Personal Use Only BODIES CABS L LINE MOTOR TRUCK SERVICE MANUAL e Page 1 BODY AND CAB GROUP SECTION A Page Cab door glasS PETT coe RRA aede OS oe Ed d TT 1 2 Cab door glass window regulator ewe were eh hh m oom oh nn TIE 2 3 Gab door Weather Strips 2 9 x Ru
91. torque of approximately 6 lbs The way to check this motor is to put a small crescent wrench on the rectangular drive on the arma ture shaft Hold the wrench in one hand hold the motor itself firmly in the other hand or in a vise and then connect one motor wire to a battery terminal and connectthe motor housing L LINE MOTOR TRUCK SERVICE MANUAL The wrench should then tend to turn with a torque or pull to the other battery terminal of about 6 lbs Allow the wrench to turn very slowly making sure that this pull or torque is present the full 360 turn of the wrench If one armature winding of the motor is burned out this torque will disappear for a small part of the 360 While making this test care shouldbe taken notto overheat the motor This motor is lubricated and sealed for life Rubber Diaphragm The rubber diaphragm between the shift unit and the carrier assembly which can be seen in Fig 8 under disassembly should be in good condition anda tightfit over the shift fork This diaphragm seals off axle lubricant from the shift unit NOTE During reassembly extreme care should be taken not to allow any dirt to enter the axle shift unit For correct positioning of diaphragm refer to lettering printed on its face Lubrication The speedometer adapter requires nomore attention than would be required by the speed ometer or the speedometer cable Several drops of light oil should be applied in the pro vided o
92. ttery wire is connected to wire C Fig 3 leading tothe other field of the axle shift unit motor and also to the speedometer adapter As shown in Fig 2 the control switch is connected to the harness or wiring system by plugging into the three pronged connector which is part of the harness The switch is removable by slipping the rubber boot up tothe knob and pulling apart Wiring System The wiring system or harness as shown in Fig 3 has four terminals Two of them b and c in a double line run to the axle shift unit on the axle Of these the longer red one is con nected to the bottom terminal and the shorter black one is connected tothe top terminal The short single black wire c is connected to the speedometer adapter and the green wire a is connected to the circuit breaker Wire d connects the copper stud of the circuit breaker to the cold side of the ignition switch The L LINE MOTOR TRUCK SERVICE MANUAL Speedometer adapter A 22629 Fig 5 Speedometer Two Speed Adapter circuit breaker protects the system inthe event ofa short circuit Should ashort circuit occur it will open the circuit until the trouble has been corrected Speedometer Adapter The speedometer adapter Fig 5 compen sates for variations in the speed of the drive shaft between high and low speed range of the axle This adapter is held in the high range by a spring and in the low range by an electro mag net The inner mec
93. u v v vv vvo oj v vj 0 0 Vs c 9m 9 09 E EA aaa NM En e 99 olo o o o o oU to LT 2 E alu a LN Mo Mo Q ua Qp Dd dd ad 0d ep oo A O oj O 01033 3 3 A O galale s ERE ERRE EEE WN jj ln ln x jo RIRIAREARIRAOAQ iQ A ime 1 i f i E o lololololo la lo luli lolinlo lo o O Ma a SO le mile e UD fe lo O lolo O ij NS je id e O O 7 Hi ha ha ho r s SB UO KO nO jo mim O B Parar Ho alin qs Eis Eg el ola fa ri gr dogs og n ono og i i AD Zz lalala AG la a jas asias ias nas glas a m m aa H 1 yv A lia Ro o elo lalola en iso mio ja lo lain cae 219 O 9 O19 9 JO O lalalala lala ojala mm wm 5 NB JSPL USB IH SP SP tt IH SP SS et te St n Sr y o2 eee a kand land land kaad land mmm mmemmmima e f PRINTED IN UNITED STATES OF AMERICA y a E GS gc NES o Jo 10 J 85 la 0 c o NE a 0 y d B 18 48 ETE E IEEE i 18 48 48 43 22 ig El E Ve Y o o o E A A J3 J555 3 O ye Do I d D U yO 2 3 see s Q4 Qu Qutieut riding UY de U ju vlo y Y i i i iM we 5 I amp das is E E E E dana A iN uu ollo ho lo mmo Ta Ol r t ja EAn v oo a xh wy e jm m N im N un 4 l i t fa Ey Fy i t i a mM le Aging a mitina lo le jolo ol e ANN jM a alain SSE Y SS ex etes e e e H jm Donated by John amp Susan Hansen For Personal Use Only REAR A
94. usting nuts from 000 end play to pre load differential bearings Adjust pre load to secure equal pre load reading at indicators See specifications for pre load data on the various axles 4 Tighten bearing cap stud nuts to specified torque 5 Install adjusting nut locks Pinion Bearing Adjustment for Correct Pre Load Torque Method After the pinion the pinion bearings and spacers have been assembled in the pinion bearing cage place the assembly in a press being sure to use a sleeve adapter as shown in Fig 15 Press the bearing down firmly and rotate the pinion cage to align the bearings and assure normal bearing contact Set press at correct pressure and attach a spring scale to pinion cage as indicated in Fig 15 Read scale only while pinion cage is turning If preload reading is incorrect the bearing load may be increased by installing a thinner spacer or decreased by using a thicker spacer The correct press ram pressure andscale reading for the various axles may be found in the Rear Axle Specifications Press sleeve Read scale only while cage turns Fig 15 shows method of checking pinion bearing preload using scales to measure torque L LINE MOTOR TRUCK SERVICE MANUAL Pinion Bearing Adjustment for Pre Load Using Dial Indicator This method should only be used on the smaller axles An outside or bench assembly should be made of bevel pinion bearings and cage With cups assembl
95. w range and if it is replace the adapter When the trouble has been traced to the shift unit disassemble as shown under disassembly and inspect the parts carefully All parts can be washed in cleaning solvent except the motor When inspecting the parts most failures wil be readily apparent however a few be readily apparent however a few assemblies should be checked as follows Automatic Switch The automatic switch 17 Fig 20 serv iced only as an assembly should have clean free moving points which close firmly under spring tension Drive Screw The drive screw 20 Fig 20 serviced only as an assembly should turn freely by ro tating the screw while holding the nut When the nut gets to the end of the screw the screw can continue to turn but the nut should not jam or run off the end By turning the screw in the opposite direction the nut will go to the other end and stop as before while the screw can continue to be turned The fiber bumper in the nut should be a tight press fit Be sure in assembly that this fiber bumper is in toward the switch The motor 6 Fig 20 serviced only as an assembly is reversible so that with the motor housing connected to one battery terminal and either one of the two motor wires connected to the other battery terminal the motor will run in one direction With the other motor wire connected to the battery the motor will run in the opposite direction The motor has a stall

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