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FRONT AXLE - Continued
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Drive Pinion, Oil Seal, and Yoke Repair (cont) - TM-5-4210-220-34_286
TM 5-4210-220-34 2-21. FRONT AXLE - Continued 2-21.2 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). b. Drive Pinion, Oil Seal, and Yoke Repair NOTE 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 during disassembly. 2-294

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