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TRUCK SERVICE MANUAL TM 5-4210-230-14&P-1 CLEANING Remove  all  dirt,  old  lubricant,  and  gasket  material from   components   of   the   rear   axle.   Immerse   in   cleaning solvent and use a stiff brush if necessary.  Bearings should be cleaned  separately  in  clean  solvent  and  special  efforts  taken to protect their finely machined surfaces.  If compressed air is used for drying, do not spin bearings while drying. INSPECTION Examine   all   bearings   for   roughness,   damage   or   wear   by rotating each bearing slowly in hand.  If in doubt as to bearing condition, replace.  Ring gear, drive pinion, differential pinions and  any  other  gears  should  be  checked  for  damaged  teeth, worn  spots,  or  distortion.    Inspect  differential  case  assembly for cracks, damage or distortion.  Make sure splined ends of axle   shafts   are   neither   twisted   nor   cracked.      Shim   packs should  be  of  uniform  thickness.    Discard  thrust  washers  and obtain new, even when only slight wear is indicated.  Always use new gaskets. The assembly of the differential carrier is accomplished in the reverse order of the disassembly.  There are, however, various adjustments which must be secured as the assembly progresses.  In addition to the adjustments there are also a few precautions to be observed.  Among these are the following: 1. Prelubricate the pinion thrust bearings when reassembling the pinion cage. 2. If  the  ring  gear  was  removed  from  the  differential case half, be sure correct rivet pressures are used in reinstalling gear to case. 3. Prelubricate   all   parts   of   the   differential   assembly before bolting case halves together. 4. When installing differential bearing caps, make sure they  are  correctly  aligned  and  that  the  bearing  cups fit  properly.    If  the  bearing  caps  do  not  seat  easily, the  adjusting  nuts  may  be  cross  threaded.    Forcing caps into place will cause irreparable damage to the differential carrier or bearing caps. 5. Observe   torque   settings   from   specifications   when tightening any parts. When  making  axle  repairs  such  as  bearing  or  drive gear replacement, or when simply making an adjustment, it is most  important  that  the  ring  gear  and  pinion  be  positioned correctly to obtain proper tooth contact.  Once the adjustment is obtained, quiet and durable performance from the rear axle is assured. Fundamentally, the correct tooth contact is obtained by moving  the  pinion  toward  or  away  from  the  ring  gear  as necessary,  or  by  moving  the  ring  gear  toward  or  away  from the  pinion.  The  actual  procedure  has  been  reduced  to  five principal steps.  Each step is vitally important to axle life and satisfactory  performance,  and  for  that  reason,  each  step  is covered more fully in succeeding paragraphs.  The five steps and   the   order   in   which   they   should   be   performed   are   as follows: 1. Preload  pinion  bearings  in  pinion  cage.    This  is determined  by  the  thickness  of  spacer  between  the two pinion thrust bearings, Fig. 18. 2. Establish pinion nominal dimension ,  Fig.  1.    Use the SE1065 Pinion Setting Gauge and add or remove shims to obtain this dimension. 3. Set gear lash between ring gear and pinion.  Do this by  moving  the  ring  gear  to  or  from  the  pinion  by means of bearing adjusting nuts, Fig. 9. 4. Preload differential bearings. This is accomplished  by  tightening  bearing  adjusting  nuts, Fig. 9. 5. Check    gear    tooth    contact.          Use     the     paint impression method for this. PRELOAD PINION BEARINGS Before the pinion and drive gear can be adjusted for correct tooth contact, the pinion bearing preload must be set. Preloading  the  pinion  bearings  is  accomplished  by  selecting the  correct  size  spacer,  Fig.    18,  located  between  the  two pinion  thrust  bearings,  and  tightening  pinion  end  nut  to  the specified torque. Temporarily   bolt   up   the   pinion,   cage   and   flange assembly, less oil seal and retainer, and clamp the assembly in a vise so as to hold the companion flange, Fig.  17.  Pinion end  nut  should  then  be  drawn  tight  to  the  torque  shown  in specifications.    The  applying  of  correct  torque  to  the  various pinion end nuts, etc.  usually calls for torque limits beyond the capacity  of  the  ordinary  torque  wrench.    Where  this  is  the case,   the   chart   listed   below   may   be   used   as   a   guide   for obtaining the torque required.  Fig. 20 illustrates the length of the  wrench  handle  (A)  and  the  effort  that  must  be  applied  at (B) when tightening to secure the necessary torque. The   cage   should   be   rotated   while   tightening   the pinion  end  nut  in  order  to  seat  and  align  the  bearings.    The rotation of the pinion bearings is important; otherwise, a false condition of bearing load could exist.  The bearing rollers CTS-2095S-CHAPTER I-Page 9 PRINTED IN UNITED STATES OF AMERICA

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