FRONT AXLE - Continued
Differential Carrier - Continued
(25) Brush surface of each friction plate making up the clutch pack (30) with gear oil (item 15, Appendix B).
Install clutch pack by inserting friction plates, one at a time, into bore of ring gear (12). Use sliding clutch (25)
to line up teeth as each plate with internal teeth is inserted.
(26) When all clutch plates are installed, insert pressure plate (28) and check once more, using sliding clutch, that
clutch plates are alined. Place clutch springs (26) on pressure plate forming the smallest possible circle.
(27) Install support case cover (11) using two 5/8 in. 18 auxiliary capscrews, 1.5 in. (40 mm) longer than the
regular capscrews (13), and nuts. Install capscrews 180 deg. apart and tighten nuts alternately until cover
(11) butts against ring gear (12).
(28) Install capscrews (13) and new locknuts (10). Remove auxiliary capscrews once two or three of the regular
capscrews (13) are installed. Tighten locknuts (10) to specified torque.
5/8 in. - 18 capscrews and nuts - 130 ft lb (175 Nm)
3/4 in. - 16 capscrews and nuts - 170 ft lb (230 Nm)
If drive pinion has not been removed from differential carrier, check carefully that no contamination has
been introduced and retained in carrier. Any foreign object can cause damage to gears or bearings.
(29) Install shift fork (56) and shaft (55) in carrier (52). Tap shaft in place using a hammer and a suitable arbor.
Install expansion plugs (54).
(30) Install sliding clutch (25) in differential and, using a hoist, place differential and ring gear assembly (7) in
carrier (52). Line up shift fork with sliding clutch. Be sure they engage before lowering assembly. Be careful
not to damage unprotected bearing cones (9 and 22).
(31) Install bearing cups (9 and 22), bearing caps (4 and 19), and adjustors (8 and 23). Be careful not to cross
bearing cap and adjustor threads.
(32) Install capscrews (2) and lockwashers (3). Tighten capscrews fingertight.
(33) Carry out adjustments of differential bearing preload, ring gear backlash, and ring gear and pinion tooth
contact as detailed in ADJUSTMENT procedures a. and b. following.
(34) When adjustments are complete, tighten capscrews (2) to 400 ft lb (540 Nm).
(35) Install locks (6) and secure with cotter pins (5). Install lock wire (1) to secure capscrews (2).
Drive Pinion, Oil Seal, and Yoke Repair
If replacement of front axle yoke (43) only is required, carry out steps 1 and 17. If front axle oil seal (42)
only requires replacement, carry out steps 1, 4, 16, and 17. Both items can be replaced with differential
installed in axle If pinion and ring gear are to be reused, record number and sizes of shims (37) removed