Contents Page
Specifications Specialtools Spareparts llustrations Rear xle ssembly Differential Limited
differential
Descriptions Flearaxle
Diflerential Limited differential
Service rocedutes
Onvehicle On vehicle epairs C h e c k i n gi m i t e dl dl i p i f f e r e n t i a.l. . . . - C h e c k i n ge n d l o a t a x f e f r " f t e " r i n g . . . . . . . . . Beplacrngi'1ron Replacing hafl earing .......... ... Removing
B1_83
c1-c7
D1-D21
axle
O i s a s s e m b l i nega r x l e . . . . . . ........ D i f f e r e n t i a l w i t h oi m u ti t e dl i p . . . .. .. .. D i f f e r e n t i ai lt h i m i t e dl dl i p . . . . . . . . . . - . . . . . . . . . . . C l e a n i n gn, s p e c t i o n -.. -.. .
F1-F13 F14-Fj7 F18_:F22
Assembling illerenlial Differentialithoutl i m i t e d s l i p . . . . . . . . . . . . . . . - . . Differentialith imi t e d s | i p. . . . . . . . . . . . . . . . . . . . . . Installinginion Installinginion .
G10-G27
Installingdifferential Inslalling axle
H1-H20 11 17
TP 30039/2 3000.06.81
Printed
34
Specilications
Specifications Rearaxle Rearaxle
qear ax e. type
Track . .
Metric Semi-floating 1350
Finaldrive
Tvpe
Reductionatio Reductionatio Type 030 Type1031 Type1031 ringgea' Backlash............ Pre-loading pinion bearings beaflngs......... usedbearings used bearings P.e-loading n oifferenLialearngs oifferenLialearngs Lubricant standard i'fere'rial . I m.red oiffprentral Viscosrly o r m a l opa'arirg co'1ditiors . when emperature steadi below l5"F -10"C
Capacity:Type Type1031 Type1031
Tighleningorques Tighlening orques
53.1s',
Hypoid 3.73:1, 4.10:1 3.54:1,3.73:1 max.0.08 0.13-0.18 25M50 0.13-0.20
0.0032' 0.005-0.007' 21-39 n.lbs. in.lbs. 0.00H.008"
-2105-B) GL-5 l\lilL-2105-B) ithadditive ithadditive GL-5 l\lilL-2105-B) for imited lipdifferential lipdifferential SAE 0
rters 1.6liters
Caps
50 70
Ringg Ring g e a r : tandardbolt tandardbolt heads f l a n g e dbolt dbolt heads.
70-80
'1.35
ft.lbs. 35-50 50-58 65-80 70-100
Wheelruls.. F l a n g e u t s . 8 6 2 6 3 / 4 "U N F ) . . 946831 3/4"U N F ) . . 947855 M20|
USmeasurements US measurements
240-300 200-250 2A0 250
175-220 145-180 145-180
Gtoup46
Specialtools
Special ools
1801 Slandard andle 1845 Press ool3/4'-16 installing rive lange 2261 Pullel round rive lange 2284 Dialgauge older adjustinginal adjustinginaldrive 2337 Tool removlngarrrer removlng arrrer 2392 Puller rear inion earing 2393 Measuring adjusting inion ill. 2284) 2394 Expanding oo removing/installing imited differential 2395 Drift installing pinion earing 2404 Wrench installingrontpinion rontpinion earing (ill. 1845) 2483 Puller dif erentialarrier erential arrier earings 2524 Work tand 2522 Fixture 2595 Adlustingings Adlustingings differential 2598 Dritt removing pinion earing uter ring ill. 1801) 2599 Drilt r e m o v i n g ' r o nitn i o n e a n g o u l e r ring nstallingifferential nstalling ifferential carrier earings 2600 Measuringixture Measuringixture adjustingings adjustingings 595, 685, 687, 2689an 2689an 2840 260'1Relainer expanding 2394 ill. 2394) 2685Adlusting 2685 Adlusting ptnton 2686 Press oo instalJinginion earing uter ings 2709 Extractor drive haft
Group46 Rearaxle
2714 Fixlure removing/installing 2779 Socket removing ropellerhaft 2806 Drift insiallingeal ndrive n drive ange 2809Holder 2809 Holder plate dialgauge 2838 Press oo rernoving/installing rive haltbearing haltbearing snap lng 2840Adlusting 2840 Adlusting pinion eight ill. 2685) 2841 Wrench adjustingings adjustingings 840, 685 nd 2689 ill. 2685) 2842Sleeve 2842 Sleeve installing pinion earing uter ring ill. 2395) 2843 Otill removing pinion earing uter ring ill. 1801) 2844 Puller rear inion earingill. earingill. 2392) 2845 Press ool install pinron edri']q urer'rngs (ir. 2686) 2846 Socket removing ropeller haft ill. 2779) 2917 Extractor brake 4112 Drilt insta differentialarrier a rrier earings 5009 Drift installingrive haft nner eal 5010 Ring install g bearing ndsnap ndsnap ing drive haft ill. 2838) 5069 Puller Pinion 5149Wrench 5149 Wrench instaliing/removing rive ange 5156 Press instal drive lange ill. t 1845) 5157Wrench 5157 Wrench ill. 2685) adjusting 5214 Ring (for ool 521515216) 5215 5P Pulter pinion earing (1030 xle) 5216 Puller pinionbearing(103'1xle)
0) O)
Speclal oo/s
1801Siandard 1801Siandard andle 2598 Drift removing Pinion earing outer 2843 Drilt removing Pinion earing outer ing
1845Piess 1845Piess ool3/4'-16 installingrive installingrive lange 2404 wrench inslallingront beanng 5156Press 5156 Press installlngrive installlngrive lange
2261Puller 2261Puller drive ange
2284Dialgauge 2284 Dialgauge older adjustinginaldrive 2393Measuringtool 2393Measuringtool adjusting inion
2337 Tool removtngarner
5215Puller 5215 Puller 1030) rearpinion earing 5216Puller 5216 Puller 1031) rearpinion earing 5214Ring 5214 Ring
2395 2842
2394Expanding 2394 Expanding removing/installing imited slipdifferential 2601Holder 2601 Holder forexpandingool2394
2395 Drift installing lreanng 2842Sleeve installing outer ing
pinion
2483
2483Puller 2483Puller differentialarrier a rrier earings
pinion earing Graup46 Rear
Specla/ ools
2520Work land 2522Fixture
2600Measuring 2600Measuringixture ixture adjustingings adjustingings 595, 685, 2687 26A9and 26A9and 2840
2709 Exlractor driveshaft driveshaft
Grouq46 Reataxle
Adlustingings differential
2685 Adiusting ing prnron 2840 Adlusting ing pinion eight 2841Wrench 2841Wrench adjustin rings 840, 685 2689 5157Wrench 5157Wrench adjusting
2/14 Fixlure removlng/installing
Drift removingrontpinion earing outer and nstalling difierentialarrier earings
2686Press 2686 Press installing inion earing uter 2845Press 2845 Press lnstalling inion earing uter rings
2779 Socket
removing ropeller haft 2846 Socket removing ropellerhaft
Specia/ ools
2806 Drift installing eal
drive lange
2838Press 2838 Press removlng/installing rive haf bearing ndsnap ndsnap 5010 0R Ring installingearing installing earing ndsnap ndsnap drive haft
2809 Holder plateand d al g a u g e
11
lr,rl Extractor 0raKe
5069Puller pinion
Drift installingif erential arrier oear
5009 Drift installing rive hafi nner seal
5149Wrench 5149Wrench install g/removingrive g/removingrive lange Gtoup 46
SpareParts SpareParts llustration AL
AL
ii ')
or&-,
Rearaxle Rearaxleassembly assembly
Gtoup46 Reataxle
SpareParts SpareParts llustration
Differential (Finaldrive)
,-:1
[-..,\6
\@
Gtoup 6
SparcPafts llustrction
{z-vtD ',t,
..*,
Description,
axle
DescrtPtton
2. Tral 5. Stabilizer
The rearaxle rearaxle s connectedo the body trailing rnrs ongitudinalforces ransfer by wo eaction orces 3)and ransversal by a track od (Panhard Trai ng arms, reaction and rack od attachedo attachedo body and ear ear xle y eplaceableubber u bber ushings. llost vehicles wagons), equipped ith rear tabilizer ittedbetween ittedbetweenhe railing rms.
Dfiveshafliournaling
oLiter oi ihe drive hafts re ournaled In raoe-oller beaflngs,Bea-_g B ea-_g crearance adtuslable determ by oearing provided design, Fig. ett.Oil seals the outside f the drive haftbearings. haft bearings.
Graup46 Graup46
Description, ditferential
Description
differential gears
shrms, djust acklash
nnggearteeth,
shims, djust ixial ocailon l h e r l n qg qgear
gear
iu ,', oeannq
{produclionnly)
shims, dlust \
beafng
The inaldrive s of he hehypoid hypoidype, ype,which w hichmeans that he drivepinion drivepinion below he center rrng gear- consists f pinion, gear differential ear.Gearbacklash Gearbacklash nd diiferenta carrier earir1gension e nsion adjusted y shims nside hedifterential hedifterentialarrier a rrier earings. Differentialarrierand arrierand ring gear assembly re journaledn the inaldrivehousing drivehousing y wo taper rollerbearings. he ring gear s attachedo attachedo the differeniialarrier differeniialarrier ybolts. y bolts. differentialgears the diiferential arrier onsistof onsistof two oevel Group
nions on a trunnionand trunnionand two side gears which shaits recarried recarried y nternal plines. ournaled o thai hey differentialears differential ears permit drive hafts o rotate otate d fierent peeds hen he beingdnven beingdnven curvesThere curvesThere s a thrustwasher ndereach ndereach differeniia ears. on bearings re aper er bearings. axial ocaton oi the nion relative o the ring gear adjusled yshims y shims nder he outer n on bearings.
Descrtptlon
Limited
differential
r ake",'antispin") {"Differentialrake",'antispin")
Exceptor Exceptor hedifferential hedifferentialssembly, ssembly, d e s i g ns ns t h e s a m e a s f o r s t a n d a r d d i f f e r e n t i a l .
\? 1 2 3 4
Differentia afiier, ma ersection Discs nternalteeth D i f f e r e n i i a l i d eg e a r e i a l n e r nq e a r D i f f e r e n l l a l i n l o nq
5 6 7 8
tr
Spider Different l carrier argerseclion D i l f e r e n i i a l i d eg e a r Dlscs, xterna eeth
shaltsmake p he spider differential plnion ears.On O n the sidewhere sidewhere t is against ditferential arrier, ach shaft has a V-shaped bevel. hedifferentialarrier differentialarrier correspondingly power roTnhe engine tarts o designed. drive hevehicle, hevehicle, shafts bevelre.es. in rhe differerrial arrer. lhis compresses rictionplates rictionplates ehind he differential sidegears o that he ditferentialssembly ditferentialssembly rabevel ngre d're'errial ar,re. designed chosenn chosen n sucha sucha way hat he hediffedifferental gearsare not entirely ocked,but ocked,but max. of engine orque orquecan can be transmittedo transmittedo a drive haft.
Group46
On-vehiclecpairs On-vehicle cpairs Limitedslipdilfercntialslip dilfercntial-
vehicle epairs Checkingimited
differential
Fabricale tool As shown n illustration ut of 3/16" steelstock. Special ool 2709can be used after necessary odif cations.
Jackup Jack up he vehicle
of the rearwheels. rearwheels. lock he other.Place other.Place gear ever n neutral. elease arking rake. move hewheel. hewheel.
Place ool ovel wheelstuds wheelstuds
Check orque
The riction orque should e: minimum maximum
the imited lip differeniial 40 t.lbs 110ft.lbs
Note he orque eading eading hen hewheel he wheel otares (rotationalriction). (rotationalriction). f torque reading s below minimum,eplace minimum,eplace iscs.
GtouP46
?i::nl:::::::; ",.u
Checking nd loaton axleshaft axleshaftbearing bearing
end loat or he axle hafts annot annot adjusreo. However, t may be necessary o determine whether end oat within cceptableimits.
Jack
vehicleand emovewheel. emovewheel.
Remove rakepads.
uller29lTf necessarv.
B2
Installmeasuring quipmenl,
a. Use ool 2809 o clampan clampan iron plateagainst ih6 hr.l6
^.lin6r'<
h^
b. Usea Usea dab grease place steel all center ole axle haft. Placehe Place he stand or he hedial dialgaugeon the ron plate.Place he dial gaugemeasuring oint (whichmust have flat surface) gainst h steelball.
Measure
loat,
The end loat shouldbe shouldbe 0.01-{.35 -0.0'i4"
0.004
To obtain otal end float, he axl e shaft must be rotated t east ne evolution bothdirections. NOTE: Prior o installation,earings installation,earingsor or the axleshafts axleshafts reater have considerably clearance. t reduced t nstallation. Repeai rocedure other xle haft.
Gtoup46 Gtoup46 Rearaxle Rearaxle
on-vehicle epairs
Replacing inion
vehicle)
Disconnecl riveshaft riveshaft use socket2 socket2 7 7 9
2846.
pinion
Checkcondition Check condition pinion and bearings. f found to be loose, he final drlve s to be removed overnauteo.
Removelange Remove langenut, a{
wrench 149.
t:-l R e m o v el a n g e . uller2261.
2261
Removeeal.
UseextractorS069. Also emove rotecting h eld.
5069
Group46 Group46
On vehicle epairs
Install
seal
Use rift2806.
Pack he newsea newsea springwith springwith 9rease.Otherwise position ounng spring ight stal Alsogrease seal ips. ll ustration: Seal
spring ith ayer f grease
Installllange.
Use ool1845 ool1845 r 5156. Torques:
1845 5156
886263/4" 886263/4"UNF): 4H00 Nm 175 220 t.lbs. 9468313/4"UNF): 0G-250 m 150-185t.lbs. 1.5): 0G-250 947855 150-185t.lbs.
Reconnect riveshaft. riveshaft.
tJse ool 2779or 2779or 2846.
Group
On-vehicle cpairc
Replacing xleshaft xleshaftbearing bearing ndseal nd seal
Preparations.
Jack pvehicle. emoveearwheel. emoveearwheel. N,4odels: emove ollision uard.
Remove rakepalts.
earaxle. Detach rake bracketrom earaxle. Remove rake aliper. ang t ol waywith waywith a prevent length steelwire steelwire o amageo amage o brake pipe.
Remove rakediscs, rakediscs,
Parking rakemustbe mustbe n he ull elease osition. Bemovehe Bemovehe wo Phillips ead crews nd brake iscs. apon apon he nside f he discwith discwith plastic ammer r similar necessary.
Remove arkingbrake hoes
Unhookand Unhookand remove he springsusing springs using brake spring liers.
Grouq46 Bear xl
an vehicle eqatrs
Disconnect arking rakecables. rakecables. Press ut he to the evers. se faLlout.
securing brake ab punch f the does
r:.try Freebearing Freebearing etainers.
(hex15mm) o free bearing bearing Rernoveour Rernoveour bolls (hex15mm) retatners.
Removeaxle Remove axle shafts. Pul axle hafts ut of rear xle ssernblysing er tool 2 7 0 9 .
Removenner Removennerseal. seal.
Use ool2337.
2838
db e a r i n g R e m o v i n gi gi r c l i p , e a r i n g n db reiainer late.
F x shaft n tool. Place oo 2 838 n a b; Adjust too so that jaws come between seal The seal \,4UST come bearing between oo and bearrng. Press i i circlipand circlip and bearing. d. Open o o . R e m o v e a r t s . Drscaro rc ll VUS NOI be'eu.ed.
Gtoup
On vehicle epairs
Prepare earing installation.
seals or
The new b e a r i n g hoLtld e completetyltled completety ltledw wt gh quality wheel bearing grease. press grease one side until greasecorneso u t o n other. Alsogrease Also grease h e n e w seals.Fill seals.Fill h e s p a c eberween e berween the ipswith ips with grease.
2838 I n s t a l l i n ge a r i n ge g e t a i n e r ,e a r i n g n d circliD. LJseool5010 LJseool5010
presso n t h e bearinq.
CIean he nterotof the rearaxle rearaxle uDe.
I n s t a l ln ln n e r e a l .
ools5009 ools5009a n d 1 8 0 1 .
Install axle shaft. Install crewsor crewsor bearing etainer. Torque:30-50Nm 30-50Nm 22-36 t.lbs. Insta brake hoe eiaining prings
Graup
on-vehicle epais
Attachbrakecables brakecables o levers.
Lubrlcate ll joints and shoe contactsurfaces contactsurfaces withheat esistantraphite rease. Press
securing rake ableso levers.
Install arkingbrakeshoes. brakeshoes.
Inspect rake ining.Reference ining.Referenceppropriate ppropriate anual ordera ordera edoroceduTes edoroceduTes neuessarv
lnstallbrake lnstallbrakediscs. discs.
Installdiscs Install discs and s ecurewith ecure with two Phillips head
Adjustparkingbrake.
Loosen able parking rake ever o remove any ension n cables. adjusting crew accessiblehrough trayhousing. trayhousing. 17 mm mmsocket socket ndextension. nd extension. djust o hat brake s fully applied appliedbetween between -3 notches brakeever brake evermovernent. m overnent. Gtaup46
on vehicle epairs
Installblake Installblakecaliper. caliper.
Attach rake new crews
bracketo bracketo rearaxle. rearaxle. brake aliper. D2
Install ollision uard. tJSAmodels.
nstallwheels.
Torque: 20 20
Group
I ft.lbs.
Removing
Removing earaxle earaxle
axle
Raisevehicle Raisevehicle lift and remove real wheels. belowhe below he rear xle, emove Withexhaust Withexhaust rom ront o rear intermediatexhaust muftler. E2
Trailing
ront ends.
Loosenhe Loosen he reiaining oltsslightly oltsslightly toa ow the trailing rms o rotate reelyat reelyat the front end when emovinghe emovinghe rearaxle). E3
Remove tabilizer ar.
Remove ear retainingbolts retainingbolts (hex 19mm) eachside eachsideof of bar. Remove ront bolts (hex 7mm) on each side and et stabilizer ar down.
emove
Panhard od).
Removeollision uards.
Group46
21
Removingea axle
On earaxle.
Disconnecthe ventiationhose. Remove lamps ding brakepipes. Djsconnect he brake pipes rear axle and secure ut ot way p r e v e n t arrage pipes.
Remove rakecalipers.
Remove wo bolts hex 1 7 m m )and ree he brake ipers leftand rrght). Remove rake ne clamp o allow some reedom ol movement the caliper. Hook the brake calipers to their respective o o r e v e n l b r a l . er r e s ' r o n b e c o m i a g drstorted.
E8
Remove rakediscs.
Parking rakemust be n the u I release osition. Remove he two Phillipsheadscrewsa n d l i f i the brakediscs on the nside f the discwith plastc hammeror simi ar ool i necessary.
E9
Remove arkingbrakeshoes.
lJnhookand remove he springs using brake sPring llers.
Grcup46
22
Removing ea axle
Disconnect arking rakecables.
Press ut he ock to the evers. fallout.
securinghe brake ables ounch f the does
Oisconnect riveshalt flange.
pinion
Use ool2779 r 2846.
Delach arkingbrake ables rom reat axte.
1. Screw Cable only emovef the rearaxle s 3. Plastic be eplaced).
Disconnecthe reaction odsat the real axte.
GrouP Rear xl
Removing eat axle
Place ixture2714 ixture2714 nder ear axle-
The ear xle oss hould est n he ixture oop.
Disconneclhe eal shockabsorbers shockabsorbers t the upperatlachments. upperatlachments.
Install pringcompressor pringcompressor springs. Compresshe springs ntil he shockabsorbers shockabsorbers detached. Then emove spring ompressor.
Remove screwsholding screwsholding he rear axle o the lailingarms. lailingarms.
Bemove he rearaxle. rear axle.
24
GtouP46 Reat xl
Disassemblingea Disassemblingea axle
Disassembling
axle
Place earaxle earaxleand and ixture2522 ixture2522 n work stand2520. stand2520. Bottom f finaldrive finaldrivehousing housingoward oward tand piniondown.
Remove
shatts.
a. Use ool 2709
pull
axleshafts. axleshafts.
b. lJse ool ool 2337 o removenner remove nner eals.
Remove
fl
erential ousing over.
Bemoveen Bemoveen screws
13 mm) o free cover.
\}
Bearing aps.
Check bearing aps marked or proper alignment ith carrier. f Ta'ks are'nissing difficulto see,mark see,markboth bothsides sideso o ensure orrect reinstallation. Remove caps.
screwshex'16 screws hex'16mm) o freebearing freebearing
Disassembling cat axle
Install ool2394.
Place ool 2394w|lh 2394w|lh rera.ners or hoLsrng. Alignpinson tool with holes n housing. crew retainer olts nlohousing. nlohousing. Tighten he tensioning crew until tool fits securely holes. hen ighten crew lowly ntil differentialssembly be removed. xceed 1/2 urns n screw.
F6
Remove ifferential ssembly,
Use ool2337. ool2337. Releaseension Releaseension n tool 2394 o prevent arrier distortion.hen distortion.hen ernove 2394. Turn he ear xle nddrain nddrain heoil. heoil.
Removelange Remove langenut. nut.
wrench5149 wrench5149and and suitabe suitabe socket.
Q,
Removelange. Removelange.
Usetool2261.
Group46 Group46
Disassemblingrcat axle
F9
Remove inion.
plaslic ammero knock ut he pinron. prevent amage, od the pinion wrth one hand s t driven ut.
Remove inionbearing.
standard andle1801and 2599 o remove frontpinion earing, asherand eal.
lf necessary: pinion earing uter ing. Remove
Rear axle type 1030: and ool 2598.
standard andle1801
Rear axle type 1031: and ool2843.
standard andle1801
It necessary: Remove pinion earing. Bearaxle ype1030: se ool 5215
Rear xle ype1031|rse oo 52'16 and ool52'14. See nextpage or nstructionsn how o apply he tool. Supersededool lluslrated).
Group46
sassem n d n Without imitedslip imitedslip
Pushpuller ver ollers nng.
press own he ock
Tighten uller crews ntil ollers re lushwith edge nner ace ndpuller. Drive ut ock ing.
Differential ithout imited emove ifferential ifferential arlierbearing.' arlierbearing.'
Use ool2483. are hould e aken ot o damashimpack. ut t asidewith emoved earing. Placepullerover bearing n ring gear side carrier. Vlake ertain hat groove tool catches on rollers. ressock ressock ingdown ingdown ool. Tighten uller ntilbearing ntilbearing off carrier. Use hammero hammero knock
he ock ing-
Repeat or other bearing.Record bearing.Record positjon bearings nd shims o facjlitatenstallation facjlitate nstallation
Remove
gear.
Place ifferentialssemblyn visewith visewith protected jaws. Remove plate A)forring earscrews. Removeen ring gear retaining crews o ree in gear.
rL
2A
Group46 Rearaxle
?^{ rr\,i.\l^U
lf ringgear ring gear ight, hreadscrews hreadscrews n partway.Ta way.Ta push gear screwsto in off. Discard he screws.Ne screws.Ne screwsMUST screws MUST be used when ssembling_
D sassemblng d ffe ent al With imited slip
Remove ifterential
shalt.
Drive out lock pjn. Drive oui dilferentiat qear snan.
Remove
erential ears.
Place he differential ssembly n stub drive shaft. ollout hesmall he small ifferentialears. arge liferentialears. liferentialears.
Differential
imited
Remove itterenlial arrierbearings.
Use ool2483. d be aken ot o damaD u r i t , s i d e \ /h r a r r o v e o b e a r i ' 1 g shin Place er over bearing n ring gear side of carrier. lake ertain hai groove n tool caiches on rolers rol ers Pressock ingdown ool. Tighten uller ntilbearing ntilbearing
carrier.
Use hammero knock ut he ock ing. Repeat other bearing.Record position bearngs and shims o facilitatenstallation arrier.
Group46 Group46
D sassembl d f et ntiat Cleaning,nspectian
Markposilion parts.
Draw ine-upmarkson differential shafts differentialarrier o hatpartsare nstalled same osition hen eassembled.
Remove olts.
Removehe boltswhichhold he differential nertogether. NOTE: Rear axle ype 1030 Inreaos.
bolts with left-hand
F2
Litl diflerential arrier. itt ditferential earplates. Remove
gear.
F2
Removeolts. iltout ringgearDlscard ld bolts. onesmustbe usedwhen reassemD F23
Cleaning,nspection paris. Clean ll parts horoughly.
Check llbearingaces bearings. Races, ollersor roller etainersmust nor oe scratchedr damaged. eplace necessary. Checkpinionand ring gear or tooth damage. Most common damage s from sejzing qear teeth, ee llustration. Damages caused contaminated r low qualityoil, incorrect ooth flank clearance laulty ooth ontact.
Gear eizure Gtoup46
D sassembl d f et nt al Cleaning, nspection
Check he different gears or tooth damage. lf anygear s damaqed, complete four malched earsmustbe repaced, Washers or the differential ears (flat or thrust) shouldbe replaced. or the largedifferential id gears ythrustwashers,/N1232436-4,reused.
b,qf.,t'.;& u t
ffiI,;:,ffi
w \,JA
srde
ul Y
washer caTrier 1232436-4
prnton
Check he drive lange ectionwhich goes theseal. eplace wornorscored..
drive lange
nion nut loses ts self-locking apacity be ng removed coupleof iimes. Replace I sealsshould be rep laced r e n t i a l s disassembled.
time the diffe-
Checkhe earaxle arrierfor racks. Check racketsor railing nd rack od or llroken and/ordamages.
,' !-
Graup46
Assem ng di lercntial Without imited slip
The utmost leanliness ustbe observed hen assemblinghe inaldrive.D irt n a tapere oller bearing an esult n enlirelyncorrectm easurements.
Bearings ustbe oiledand otated everaltimes under oad beforemeasuringearing learance pretoao.
Ditlerential ithout imited
Constructool.
Bolts, and washers ccordingo the ollowing isting ecommended o help nstall difterentiale ars. wo bolts Tw nuts Fourwashers
1/2"x3-1/2" M12x90) 1/2" M12) 1-3l8"x /8" 3 rnm)
Cut wo washers s shown o that heycan be fitted verthe olts.
Fit hrustwashersand argedifterential gears. Place Pushn Install
washer nd eachbolt. boltwith hehead irst. slotted asher.
Compress. Tighten
\-=
GrouP Bearaxle
nuts o compresshe hrustw ashers.
Assem l ng d ff et ntial without imitecl lip-
I n s t a l l m a l l i f f e r e n t i a le a r s thrustwashers.
Roll n smalldifferential e a r sand hrustwashers an assemb
Remove olt ools.
lnstalldifferential
shalt.
lnstal shaftand ock p i n . P u n c h o l o c k t h e l o c pin.
Reassembledif erential. Insta ringgear n carr assernbly.ake ure contactLrriaces f burrs. Use new bolts. The bolts are tightened limitand cannot reused.
yield
[Jse a ternate side p a t t e r n or tightening bolts. Torque o: Standard olt h e a d :7H0 Nm 5 0 - 5 8 t.lbs. :65-80 ft.lbs. Flanged o t head:9 0 - 1 1 0
O p e r a t i o n sG 8 a n d G g c o n t a i n s p e c i a l assembly nstructionstor limited sllp differenllat.
Common installation insttuclions continue wilh G10.
Group 6
Assem l ng d f ere tial _ t imito.t
.ti^.till
Differential ith imited liD Inspecting
Before nspecting, parts horough solvent. check heparts arefuly or wear, cracks r oiherdamage. aulty arts houtd replaced.f any discs equire eplacement because f abnormal ear, ll the discsshou be eplaced t sarnelme.
Use new bolts and lock fluid. The bolts are tightened d limits ndcannot e eused. Use lternate Torque
ightening attern. 50-58 t.lbs. 65-80 t.lbs.
prev ous differentialswhere boih the differential gears and the differentialgear r e t a i n e r s have splines or the drive shafts, he spl nes must be algwith the help of the drive shaftswhen he bolts are ighte-
l,
5. Dished lsc,2 0.1" =01" Flal isc,2.4 7. HUb 8. Large ifferential ears L Shalls Sma dilferenlial ears
gearon carrier ssembly. ake Install contact urfaces clean nd reeof burrs.
Standard head: 0-€0 Flangedo head: 0-1'10
fr
1. Bot 2. Differenlialhousing Disc,15 0.06
Reassemble ifferential
f,? l0
Install hafts, ears
discs
Lubricate ach part before nstallation. Place the discs and o t h e r p a r t s the order shown n il ustration n the ring gear half different housing. A ign the dlscs and fit the smaller half of the differentialcarrier. Install he bo ts.Torque o: 60-75 Nm 44-55 ft.lbs.
Group Rearaxle
Assembling ea axle
I n s t a l l i n gi n i o n 2685 2a4A
Install ools
pinion
Finaldrive Adjustinglng Wrench
T 30 2685 2841 (5157)
Use extremelyine emerycloth to clean p i n r o nh o u l d e r Install djusting ng andwrench /]ake ure he ockingscrewol t he adjusling ing is open posrtron. 1031 2840 2841 (s157)
Position inion n carrier
Screw Iargepart
the adjusting ing carrier.
Make s u r e h e
m!st face he
on the adjusting ng is In
Measurement
pinion must have a set distance to the gear flng center line. Due to t olerances n the manufacturing,here are deviations rom the set distance. hese deviations r e indicated pinion. deviation always and in hundplus sign omitted. redths f amillimeier. Conversionable m ll meters o inches
mm
nches
Trm
inches
0.20 o.21 o.22 o.23 0.24 o.25 0.26 o.21 0.28 0.29 0.30
0.0079 0.0083 0.0087 0.0091 0.0094 0.0098 0.0102 0.0106 0.01'10 0.0114 0.0118
0.31 a.32 0.33 0.34 0.35 0.36 4.37 0.38 0.39 0.40
0.4122 0.4126 0.0130 0.0134 0.0138 0.0142 0.0146 0.01s0 0.0154 0.0157
Group 6
Assemblingea axle
Checking inion ocation use: dial ndicator indicatoretainer 284 measuring 2393
pans: Measuring 2393 onsists pinion auge adjusterixture.
ZEROINLOCATION
Alignmeasuringools
Locate ndicatoretainer o hat he dial ndi cator ip ouches adjusterixture.
22A4
It_.,
Measure istance piniongauge
Move he indicator etainer o that ihe dial
cator ip ouches pinion auge. pinion auge hould eflecthe igure ndicapinion. pinron example: marked .33, pinion auge hould ie0.33 below headjusterixture. Adjust y urning he wrench f the ninionuntil dial ndicator hows orrecteading. lJse he ocking crew o lock hewrench.R emopinion. measuringools
Shim hickness,
pinionbearing
Position ear pinion bearingassembly measuringixture 600. nstall late, pring (flat side up). Rotate plate and bearing assembly and orth everaltimeso hat he rollers ssume orrect ositions. Position djusting n measuringixture. Jse etainer 284 nddial ndicator Positionhe dial ndicatorip againsthe adjusting ing o zero.Thenchangehe ip locationo thebearing uter ing. hedial ndicashows equiredhickness f shims. Removeearing ndmeasuringixture 600.
Gtoup46
Assembling ea axle
Measurehim hickness
micrometer. NOTE: It is very difflcui to obtain absolutely orrect shim hickness. ollowing eviations permitIeo:
0.02 0.05
0.0008" 0.002"
Install earpinionbearing n pinion Use ools:
2395 Type 2842orType NOTE: First a rearpinion earings removed,h ere is a spacer asher nder he rearpinionbearing inner ing. t rust einstal
Installp inionbearing ings
Position hirn determined oeanng. l11staluter ings or pinion ings. LJseoolsl 2686orType 030 2845orType 031
r e a rp i n i o n ront bear-
Installpinion
P o s i t o n n i o n . n s t a l t h r e e h ir n s . 7 5 rontpinion earing. 0.03"thlck Insta wrench 404 ndpress lS45(alt.5156) p i n i o nr o n t ress pinion NOTE: nion orward using nut runner, ress that does he bearing aceswith mpact
GrauP
Assenbling ea axle
Installpinion
Remove ool 1845.Lei wrench2404 emain place. Install inion Torque Nm 185 t.lbs.
Shim hickness,ront pinionbearing
Install iniongauge, ial ndicator eta,ner dial ndicator. o w n h ep i n i o n h i l e u r n i n g backand orth at the same ime.Zero he dial In0tcalor. Press pinionup whi turning and orth. Read dial ndicator.
Adiust
pack hickness
pinion o rerrove
bearngs: remove shims according o dial indtcator reading 0.0035". Previously earing: rernoveshims according o dial indicator read PLUS 0.0028"
Installpinion
Positionpinion. n s t a l shim pack determi11ed lro.r p r ' 1 , o n irg. Install ronr nion beari'1g. Installwrench p r e s s oo 1845(att.5156) piniolr r o n t end.Press n pinion. NOTE: lf usinga nut runner,press pinlon orward that i does not hit the bearing aceswith impact iorce.
Group
Assemblingea axle
Install inion
Remove1001 845. Let wrench 2404 renaln in place Instal washer nd nut.Torquen u t o l 185 t.lbs.
Check inionbearing reload Use orque auge. orreci reload:
bearingsr50-450 cm 21-39 n.lbs. U s e d a a r i r g s6 0 - 1 1 0 c m l0 | lb:.
2284 C h e c k i n i o no c a t i o n
Use dial indicator, elairet 2284 and measuring tool2393 Zero-set he
indicalor againsi the adluster
IIXIUTE,
Shift d i a l n d i c a t o ro t h e p i n i o n a u g e check hepinion Pinlon ocatlonmust not deviate rom correct posit morehan: -0.02mm-00008" 0.05 0.002"
Group
Assemblingea axle lnstalling iffetential
Installingdifferenlial
Install diusting ings
adjustingings 595-nstall n differential. Black-oxldizeddjusting ringgear ide. H2 bearing eats n rear xle. Position ifferentia adjusiingings ssembly ear xle.
Ad,ust acklash
Adjust adjustlngings part ntil he differential s held irmly !t notpreloaded. Positionhe dial rndicator. et he ip approx.3 1/8"from f ringgear ooth. pinion Hold he move heringgearback forth. Note he backlash. llowedbacklash s 0.12-0.18 m 0.005-0.007',u t shouldbe set near0.15 m 0.006"aspossible. Adjustby turning both adjusting ings same irection.
Attercorrectbacklashs obtained
Lock adjustingings n position. Remove itterential nd adjusting ings assemoty. H5
Determine him hickness
NOTE: Alwaysemember side whichbearings shims re o be nstalled. Position ceniering late nreasuringixture 2600. osition bearing n he measuring ture. nstall late, pringand nut (flat sideup). Rotateplate bearingassembly ack and forth severalimes so that the rollersassume correct osition. Posilion djusting 1)on measuringixture. Instal etainer dial ndicator Positionhe dlal ndicatorip againsthe adjusiing ring 1)and et o zero. henchangehe ip location o the bearlng. ote he dia indicaior reaorng. GtouP46
Assemblingea axle lnstalling iflerential
Measure him hickness
lJsemicrometer.otal him hickness hould noted alue LUS .07 0.0028".
Repeat rocedure
olher side
H8
Installbearing pposite
gear
Installdetermined him pack. Use drilt 4'112 whenpressing n bearing.
H9
Install earing, inggear side
plate A) or ring gear bolts,deterInstall mined himpack bearing. bearing. Use rifl4l 2 press drift 2599on the bearing pposite ide prevent ama9es.
Install itferentialassembly
Use retainers 601 position xpanding ool until t its 2394 n rear xlehousing. xpand securelyn holes n housing. hen ighten he screw nadditional 3.5 urns. Position ifferential iih bearing uter ings n rear o0sing, Bemove xpanding 2394.
Group 6 ReatAxle
Assemblingea axle lnstalling lferential
Install ealingcaps
Check markings. orque bolts to 50-70 Nm 35-50 t. bs.
Check backlash Allowed acklash 0.12{.18 sho!ldbe as near0,15 lble.
0.00H.007" 0.006" s poss-
Remove rench 402,
Install slinger nstall
oil seal
Pack pringof new oil sealwith grease.Otherwise he coil may out of positiono u n n g installation. rease ealing ips. Oilseal 2. Spring ilh rease tJse rift2806o nstall
seal.
Installpinion lange resstool
Install
or5156).
Torques: Nut 886263/4"UNF)24G.j00 m 17s-220t.lbs. 9468313/4"UNF)200-250 145-185t.lbs. Nu 947855N,,120 1.5) 200-250Nm t.lbs. Gtoup
42
Assembling rear axle stal n er n t al
Install asket
covel
....5009 '1801
Install riveshaftseals
dr it 5009and handle1801.
NOTE: spacebet\,!een ealing ipswith grease. Also iil space between roller reta bearing nner ing with grease.
Installdrive shafts Torque olts or 40 t.lbs.
o 30-50
Fillwithcorrect ubricanl Capacity:
1030: ilers 1.35 qts. qts. 1 0 3 1 : . 6i t e r s Fina drive il SAE
GL-s
GrouP
21058
lnstalling earaxle
Installing
Prepare nstallation
Positionear xle n ixture 714. ositionixture and ear xle nder ehicle.
12
Attach railingarms Install
bolts inger ight.
Also nstall bracketsor hesiabilizer attachments.
Attachhe rearshock bsorberst upper ttachments
Install pring ompressors040 ndcompress springs o hat heshock bsorbers installed. Make ure hewires olding brake alipers do notbecomenvolved. Remove spring ompressors.
14
Remove he ixture
Group Rearaxle
lnstalling cat axle
Atlach eaction ods Donottighlen.
16
Attachparkingbrakecablesat the reat axle Screw Cable Plastic
17
Connect riveshatt o flange Use ocket 779 r2846.
Connect arkingbrake ables
Group46 Reataxle
lnstalling earaxle l9
Installp arkingbrakeshoes
Installb rakediscs
Install crewsetaining rake iscs
11
Install rakecalipers
Connect rake ines
Attachbrackets clamps ecuringhe brake lrnes. Hook retainingprings f parking rake cableso upper lamps.
:r13 Reconnect rearaxle Group46 Bearaxle
venlilation ose o the
lnstalling ear axle
Install ollision uards
Installthe rack od Panhard
Install
Rear
Torque.
slabilizer
Lower nd ock heca beioreighlening. seTorque SpecsChart.
Rear end torqu€s
ft. lbs.
Reaction rod: Bodyanachment..... Rearaxlesttachm€nt Trsd< rod (Ponh6rd odl: Rearaxleattachment Bodyattachment.....
62
Roar spdng: Upperattachment Low€rattachment,... Shod
115 ... ...
85
lalional
Irstituteor luT0trl0ItvE SERVIGE ETCEIIEIGE
VOLVOUPPORTS I)LUNTARY MECHANIC E RTIFICATIOI{ lY THE t.A.S.E. {U.S.A.. ly)
