Diesel Mechanic: Module ODF-1

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DIESEL MECHANIC

CODE: ODF-1

STRIP, CLEAN AND

INSPECT A DIFFERENTIAL
AND FINAL DRIVE
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INDEX
The following elements are contained in this learning guide:

TOPIC PAGE NUMBER

Index 2
Source reference 3
Objective 4-5
Hazard Identification and Control (HIAC) form 6-7
Condition report on differential and final drive 8 - 11
Introduction 12
Rear drive axle assembly 13 - 14
Hypoid and spiral bevel gears 14 - 15
Crown gear teeth nomenclature 16 - 17
Pre-load and backlash 18 - 19
Types of rear axle carriers 19 - 20
Operation 20 - 22
Self test 1 23 - 24
Final drive 25 - 27
Self test 2 28
Stripping the final drive 29 - 34
Practice 34
Dismantling the differential 35 - 42
Practice 43
Cleaning and inspection 44 - 51
Practice 52

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SOURCE REFERENCES

Demonstration by a competent person, e.g. a Training Officer.

Makers’ catalogues and service manuals.
Models in the training centre.

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OBJECTIVE
You will be learning towards the outcome “Strip, clean and inspect a differential and final
drive”. Whilst learning towards the outcome you will be required to achieve the following:
 Strip, clean and inspect the differential and final drive.

On completion of this module, the learner must be able to:

 Describe the operation of the differential and final drive.
 Strip the differential and final drive.
 Clean the differential and final drive.
 Inspect the differential and final drive.
 Complete the condition report

During this process you must adhere to certain specified requirements as listed in the
Module.

ASSESSMENT AND EVALUATION CRITERIA

You will be assessed, when you are confident that you may achieve the outcomes as listed,
to determine your competence as measured against the required criteria. This assessment
will be in line with accepted best practices regarding assessment.

 A practical test will be set at the end of the module and must be completed without using
references.
 For the practical test, the learner will be given a rear axle with a differential and final
drive and all the necessary tools and equipment.
 The following standards must be achieved:
a. The operation of the differential described correctly.
b. The operation of the final drive described correctly.
c. The differential stripped in the correct sequence.
d. The final drive stripped in the correct sequence.
e. All the component parts were thoroughly cleaned.
f. The condition report correctly completed.
g. There must not be any damage to any fasteners.
h. There must not be any damage to tools and equipment.
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i. All safety procedures must be adhered to.

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HAZARD IDENTIFICATION AND CONTROL (HIAC) FORM

ODF-1

STRIP, CLEAN AND INSPECT A DIFFERENTIAL AND FINAL

DRIVE
STEPS IN OPERATION / POTENTIAL ACCIDENT / CONTROLS (BY
PROCESS INCIDENT RESPONSIBLE PERSON)
1. Use hand tools.  Using damaged tools or  Always use the correct
wrong tools for the job tool for the job.
can cause injury and  Ensure tools are in good
damage to equipment. condition.
 Use tools correctly.
 Wear appropriate PPE
where necessary.
 Always take good care of
tools. Maintain, clean and
store it properly.
2. Work on machinery.  Injury to person if working  Ensure that power to the
on moving machinery. machine is switched off,
and if possible, physically
locked out. Place a
warning sign stating:
“Men at work. Do not
switch on” in a prominent
position.
 Ensure that machinery is
stationary before
commencing work.
 Replace machine guards
after completing the task
an before starting the
machine.

NOTE: Before doing the practical work contained in this module, the learner must study the
content of the above HIAC form again and then sign the statement below.

The above risks, which will be encountered in this module, are fully understood and will be
controlled during the practical work.

Signature of learner:

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Signature of Training Officer:

Date:

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CONDITION REPORT ON DIFFERENTIAL AND FINAL DRIVE

1.PINION GEAR SHAFT ACCEPTABLE NOT ACCEPTABLE

Gear Teeth

Bearing Surfaces

Seal Surface

Bearings

Seals

Retaining Nut

Threads on Shaft

Pinion Shaft Splines

Remarks:

2. CROWNWHEEL ACCEPTABLE NOT ACCEPTABLE

Gear teeth

Bearings

Thrust nut (if applicable)

Remarks:

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3. SPIDER GEAR ASSEMBLY ACCEPTABLE NOT ACCEPTABLE

Spider Gear Teeth No.1

No.2

No.3

No.4

Side Gear Teeth No.1

No.2

Clearance Spider Gear Shaft

No.1

No.2

No.3

No.4

Roller Bearings

Bearing Surfaces

Thrust Washers

Splines on Side Gear No. 1

No. 2

Remarks:

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3. FINAL DRIVE ASSEMBLY ACCEPTABLE NOT ACCEPTABLE

Gear Teeth on Sun Gear

Gear Teeth on Ring Gear

Gear Teeth on Planet Gears

No. 1

No. 2

No. 3

No. 4

Clearance Planet Gear/Shaft

No. 1

No. 2

No. 3

No. 4

Planet Gear Thrust Washer

No. 1

No. 2

No. 3

No. 4

Remarks:

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5. SIDE SHAFT ACCEPTABLE NOT ACCEPTABLE

Splines

Bearing Surface

Seal Surface

Bearing

Shaft (bent/broken)

Remarks:

6. Carrier housing cracked Yes No

7. Threaded holes in housing Yes No

stripped

Remarks:

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INTRODUCTION
ITEM / TASK: Introduction

DESCRIPTION:
In Modules OMT and CLU it was explained that the clutch in a power train is used to
disconnect the engine from the power train, allowing the engine to run while the machine is
standing still. The clutch also engages the power train to move the machine. See Fig. 1.

Fig 1

A transmission enables changes in the speed of the drive wheels in relation to the engine
power. This allows slower speeds when starting to move the machine and faster speeds to
match various loads and conditions. In this module we will cover the transmission up to the
drive wheels by explaining the function of the differential and final drive.

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Rear Drive Axle Assembly

It consists of the following parts:

Pinion drive gear—transfers power from the drive shaft to the ring gear.
Ring gear/ Crown wheel—transfers turning power to the differential case assembly.
Differential case assembly—holds the ring gear and other components that drive the rear
axles.
Rear drive axles—steel shafts that transfer torque from the differential assembly to the drive
wheels.
Rear axle bearings—ball or roller bearings that fit between the axles and the inside of the
axle housing.
Axle housing—metal body that encloses and supports parts of the rear axle assembly.
Final Drive - to further reduce speed and increase torque to move bigger loads

Functions of a Rear Drive Axle Assembly

A rear drive axle assembly has several functions:

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1. Sending power from the drive shaft to the rear wheels.

2. Providing a final gear reduction.
3. Transferring torque through a 90° angle.
4. Splitting the amount of torque going to each wheel.
5. Allowing the wheels to rotate at different speeds in turns.
6. Supporting the rear axles, brake assemblies, suspension components, and chassis.
Hypoid and Spiral Bevel Gears
Hypoid gears have the driving pinion centreline offset, or lowered, from the centreline of the
ring gear. Modern differential ring and pinion gears are hypoid type. Refer to Figure 4.
Spiral bevel gears have curved gear teeth with the pinion and ring gears on the same
centreline. This type gear setup is no longer used.
Hypoid gears have replaced spiral bevel gears because they allow for a lower hump in the
vehicle floor and improve gear meshing action.
Hypoid gears have a larger gear tooth contact area than spiral bevel gears. This helps
increase gear life and reduces gear noise.

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The exploded view shows all the major parts of a differential assembly.
The Crown / Ring gear bolts to the differential case.
The carrier bearings are adjusted using large nuts.
Study the part names and how they fit together.

OPERATION

• The differential case with ring-gear, and the drive pinion are mounted in
opposed taper roller bearings in the one piece rear axle carrier.
• The rear axle drive pinion receives its power from the engine through the
transmission and drive shaft.
• The drive pinion rotates the differential case through engagement with the ring
gear, which is bolted to the differential case flange.
• Inside the differential case are two differential pinions (planetary gears)
mounted on the differential pinion (Planetary)shaft, which is pinned to the
housing.
• These gears are engaged with the side (sun) gears, to which axle shafts are
splined. Therefore, as the differential housing turns, it rotates the axle shafts
and rear wheels.

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Crown gear teeth nomenclature.

Study the names, they are needed when reading or interpreting gear contact

Pinion gear depth refers to the distance the pinion tends into the carrier. Pinion gear depth
affects where the pinion gear teeth mesh with the ring gear teeth. Pinion gear depth is
commonly adjusted by varying shim thickness on the pinion gear and bearing assembly.
Fig.7 illustrates how shims affect pinion gear both removable and integral carriers.
Pinion bearing preload is frequently adjusted by torquing the pinion nut to compress a
collapsible spacer. The more the pinion nut is torque, the more the spacer will compress to
increase the preload (tightness) of the pinion bearings.

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The outer end of the pinion drive gear is splined to the rear universal joint companion flange
or yoke. The inner end of the pinion gear meshes with the teeth on the ring gear. The pinion
gear is normally mounted on tapered roller bearings. They allow the pinion gear to revolve
freely in the carrier. Either a crushable sleeve or shims are used to preload the pinion gear
bearings. Gear preload is a small amount of pressure applied to the bearings to remove
play and excess clearance.

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With some differentials, the extreme inner end of the pinion gear is supported by a pinion
pilot bearing. This is a straight roller bearing. The pinion pilot bearing helps the two tapered
roller bearings support the pinion gear during periods of heavy load. See Figure 9 on
previous page.
The ring gear is driven by the pinion gear and transfers rotating power through an angle
change of 90º. The ring gear has more teeth than the pinion gear. Bolts hold the ring gear
securely to the differential case.
The ring gear and pinion gear are commonly a matched set. They are lapped (meshed and
spun together with abrasive compound on their teeth) at the factory. Then, one tooth on
each gear is marked to show the correct tooth engagement.

When a solid spacer is used, pinion gear shims commonly control pinion bearing preload.
The pinion nut is usually torqued to a specific value; decreasing the shims thickness will
increase the bearing preload.
Carrier bearing preload is the amount of force pushing the differential case bearings
together. As with pinion bearing preload, it is critical.
If Carrier bearing preload is too low (bearings too loose), differential case movement and
ring and pinion gear noise can result. If preload is too high (bearings too tight), bearing
overheating and failure can result.
When adjusting nuts are used to set case bearing preload, the nuts are typically tightened
until all the play is out of the bearings. Then, each nut is tightened a specific portion of a
turn to preload the bearings. This is done when adjusting backlash (covered shortly)

Ring gear and pinion backlash refers to the amount of space between the meshing teeth of
the gears. Backlash is needed to allow for heat expansion and lubrication.
As the gears operate, they produce friction and heat. This makes the gears expand,
reducing the clearance between meshing teeth. Without sufficient backlash, the ring and
pinion teeth could jam into each other as they reach operating temperature. The gears
could fail in a short time. Too much ring and pinion backlash could cause gear noise
(whirring, roaring, or clunking).

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Ring gear run-out is the amount of wobble (side-to- side movement) produced when the
ring gear is rotated. Ring gear run-out must be within specifications.
To measure ring gear run-out, mount a dial indicator against the back of the ring gear. The
indicator stem should be perpendicular to the ring gear surface. Then, turn the ring gear
and note the indicator reading. See Figure 11.

Two basic types of rear axle carriers.

A removable carrier is handy because it can be serviced at a workbench.
Integral or unitized carrier is formed as part of the axle housing.( Local Differential)

See Fig 12 on the next page.

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OPERATION
In the rear axle the ring gear and pinion transmits the power "around the corner" to the
axles as shown in Fig. 13.

If it was only necessary to travel in a straight line, that is all the gearing would be needed at
the rear axle, but when a corner is turned, the outside wheel has to travel a greater distance
than the inside wheel in the same time. (Fig.14).

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Driving straight ahead:

The differential will transmit power to both wheels, to propel the load when the machine or
vehicle is moving straight ahead, or taking a gradual bend when the wheels are turning at
different speeds. See Fig. 15.

Engine power comes in on the pinion gear and rotates the ring gear. The four bevel pinions
and the two bevel gears are carried around by the ring gear and all the gears rotate as one
unit. Each axle receives the same torque and so each wheel turns at the same speed.

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Turning corners:
When the vehicle turns a sharp corner, only one wheel is free to rotate as shown in Fig. 16.

Again, engine power comes in on the pinion gear and rotates the ring gear, carrying the
bevel pinions around with it. However, the right-hand axle is held stationary and so the
bevel pinions are forced to rotate on their own axis and "walk around" the right-hand bevel
gear.
Since the bevel pinions are in constant mesh with both bevel gears, the left-hand bevel
gear is forced to rotate because it is subjected to the turning force of the ring gear, which is
transmitted through the bevel pinions (Fig.16) through the sun gear to the outer wheel.

During one revolution of the ring gear, the left-hand bevel gear makes two revolutions - one
with the ring gear and another as the bevel pinions "walk around" the other bevel gear.
Therefore the speed of the outer wheel will increase with the same amount that the speed
of the inner wheel had decreased.

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SELF TEST 1
Answer the questions below without referring to your notes:

1. Name the parts of a rear drive axle assembly

_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________

2. What is the function of the differential?

_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
________________________________________________________________________
_________________________________________________________________________

3. Describe the operation of the differential when:

a) The vehicle is moving straight ahead.

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

b) The vehicle turns a sharp corner.

_______________________________________________________________________
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_______________________________________________________________________
_______________________________________________________________________

4. Define backlash
_________________________________________________________________________
_________________________________________________________________________
________________________________________________________________________

5. Define bearing pre-load

_________________________________________________________________________
_________________________________________________________________________
________________________________________________________________________

6. Describe how the Ring Gear run-out is measured

_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
________________________________________________________________________

Ask your Training Officer to check your work and if it is correct, to sign below and then go
on to the next section.

LEARNER TRAINING OFFICER

DATE : DATE :

SIGNATURE : SIGNATURE :

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FINAL DRIVE
Some machines like Trucks, Tractors and earthmoving equipment have final drives on the
axles to further reduce speed and increase torque to move bigger loads. Refer to Fig. 17.
The main types of gearing used are planetary gears.

Planetary gears are simple in design, but their operation is not always understood.
Planetary gears are similar to the solar system (Fig.18).

Each planet pinion gear turns on its own axis while rotating around the sun gear. This is
much like the earth and other planets rotating around the sun. The pinion gears in turn
mesh with the inside of the ring gear.

When power is applied to drive the sun gear or the planet pinion carrier, the entire system
will rotate as a unit unless a restraining force is applied to hold one of the other two
members of the system stationary.

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When power is applied to one member of the planetary system, and a brake is applied to
restrain a second member from turning, the remaining part will become a power output
source.
Operation of a final drive

The planetary gear reduction system receives engine power from the differential through
the final drive shaft and sun gear. The sun gear is an integral part of the final drive shaft
and this turns with the shaft (Fig. 19). The sun gear meshes with the planet pinions which
are mounted in the planet pinion carrier.

As the sun gear turns, it forces the planet pinions to "walk around" the inside of the ring
gear as shown by the arrows in Fig. 19. The planet pinion carrier is forced to rotate in the
same direction as the sun gear, thus delivering engine power to the drive wheels, but at
reduced speed and at increased torque to move bigger loads.

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Go on to the next page to do the self test.

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SELF TEST 2

1. What is the function of a final drive?

_________________________________________________________________________
_________________________________________________________________________

2. Describe the operation of the final drive.

_________________________________________________________________________
_________________________________________________________________________
________________________________________________________________________

Ask your Training Officer to check your work and if it is correct, to sign below and then go
on to the next section.

LEARNER TRAINING OFFICER

DATE : DATE :

SIGNATURE : SIGNATURE :

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STRIPPING THE FINAL DRIVE:

1.Fasten a hoist to the tyre and rim.
2.Remove the tyre and wheel assembly.

Fig 20
20

3.Turn the hub assembly forward or to the rear until drain plug (3) is in the downward
position
4.Drain the oil from the final drive.
5.Remove bolts

Fig 21
20

6.Remove cover assembly

7. Check the 0-ring seal in the cover for wear or damage. If necessary, make a
replacement
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Fig 22
20

8. Remove 0-ring seal (4) from the cover assembly. Remove four bolts (6) then remove
plate (5)
from the cover.

Fig 23
20

9. Install a 7/16’’-l4 NC forged eyebolt (4) in the end of the drive axle as shown.

Fig 24
20

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10. Pull drive axle out of the final drive approximately 38.1 cm.
Fasten a hoist to the drive axle. Remove drive axle (5). The weight of the drive axle is 34
kg.

Fig 25
20

11. Remove retainer ring (6) from the axle shaft. Remove gear (7).

Fig 26
20

12. Remove three bolts (1) that hold the final drive planet carrier to the wheel assembly.
13. Turn the wheel assembly so drain plug (2) is at the top of the wheel assembly

Fig 27
20

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14. Pull the final drive planet carrier forward on the studs approximately 38 mm.
15. Install tooling (A) on the planet carrier as shown.
16. Fasten a hoist to the planet carrier.
17. Remove final drive planet carrier (3). The weight of the final drive planet carrier is 79 kg.

Fig 28
20

18. Check the 0-ring seal on the planet carrier for wear or damage. If necessary, make a
replacement

Fig 29
20

19. Put retainer ring (4) under compression. Slide ring gear (5) forward so that the retainer ring can
not go back into the groove in the ring gear.
20. Put tool (B) in position in the groove of the ring gear as shown. Fasten a hoist to tool (B).
Remove the ring gear. The weight of the ring gear is 24 kg.

Fig 30
20

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21. Lift three shafts (1) out of the carrier.

Fig 31
20

22. Remove the shafts (6) from the carrier. Also the thrust washers and gears

Fig 32
20

23. Inspect and measure the planetary shafts and compare to specifications
24. Check the condition of retainer rings (5), replace the parts if necessary

Fig 33
20

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25. Check the condition of gears (4). bearings (I) and (3) and spacers (2), replace the parts
if necessary

Fig 34
20

PRACTICE

Referring to these notes and the workshop manual, practice stripping the final drive.

Ask your Training Officer to check your work and if it is correct, to sign below and then go to
the next section.

LEARNER TRAINING OFFICER

DATE : DATE :

SIGNATURE : SIGNATURE :

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Dismantling the Differential

* Use a centre punch to match mark the differential carrier caps to carrier assembly.
This is to ensure correct match in reassembly (Fig. 35).

* Remove the lock wire and the differential adjusting nut lock.
* Remove the bearing cap bolts and bearing caps (Fig. 36).

* Insert a metal bar through the differential and raise it from the carrier assembly (Fig.
37 on the next page).

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* Remove the locking device securing the pinion shaft nut to the pinion shaft.
* Position the socket on the pinion shaft nut.
* Install the flange retainer tool on the flange (Fig. 38).

* Remove the shaft nut and washer.

* Remove the companion flange from the pinion shaft with a puller (Fig. 39).

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* Remove the bolts securing the seal retainer to the carrier and remove the retainer
(Fig. 40).

* If necessary, tap with a soft mallet to break the seal between the parts.
* Drive the seal from the pinion oil seal retainer. If required, screw two "jack" bolts in
the holes provided and pull the bearing cage from the carrier assembly (Fig. 41).
This pulls the outer pinion bearing cone from the shaft.

* Turn each bolt equally to prevent damage to the carrier, shaft or bearing.
* After the bearing cage is pulled out a short distance, back off the puller screws and
insert shim-stock or plate under the puller screws before pulling is continued. This is
to reduce possible damage to the shim-pack under the flange of the bearing cage
(Fig. 41).
* Remove the pinion shaft assembly from the carrier (Fig. 42) on the next page..

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* Remove the bearing cage shims.

* Retain the bearing cage shim-pack intact for possible re-use in reassembly.

Disassembling the differential case and ring Gear

* Match mark the case halves to ensure correct reassembly as shown in Fig. 43.

* Remove the differential bolts securing the case halves together.

* Lift off the plain case half (Fig. 44) on the next page.

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* Remove the spider, pinions and thrust washer (Fig. 45).

* Remove the nuts and bolts and remove the ring gear (Fig. 46).

In some configurations the ring gear is rivetted to the ring gear mounting surfaces.

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* Remove the differential bearing cones (Fig. 47 ).

* Press the pinion shaft from the pinion bearing cage assembly (Fig. 48).

* Press the centre pinion bearing cone from the pinion assembly (Fig. 49).

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* Remove the inner pinion bearing snap ring if applicable.

NB: Some pinion shafts have the inner pinion bearing staked to the pinion shaft,
thus replacing the retaining ring feature.
Staking is a form of nicking a shaft or sleeve to lock it in position (Fig. 50).

* Remove the staking before pressing the bearing from the pinion assembly, using a
suitable small file.
* Press the inner bearing from the pinion assembly (Fig. 51) on the next page.

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* If worn or damaged, drive the bearing cups from the pinion bearing cage (Fig. 52).

Go on to the next page for the practice.

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PRACTICE

Referring to these notes and the workshop manual, practice stripping the final drive.

Ask your Training Officer to check your work and if it is correct, to sign below and then go to
the next section.

LEARNER TRAINING OFFICER

DATE : DATE :

SIGNATURE : SIGNATURE :

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Cleaning and Inspection

Clean all parts thoroughly using solvent type cleaning fluid.

a) Bearings

* Remove the bearing from the cleaning fluid.

* Strike larger side of the cone flat against a block of wood to dislodge solidified
particles of lubricant.
* Immerse the bearings in cleaning fluid again to flush out the particles.
* Dry the bearing using compressed air.
NB: Be careful to direct the air stream at 90° through the bearing to avoid spinning
it (Fig. 53).

* Oil the bearings immediately after cleaning and wrap in a lintless cloth to prevent
rusting. (Refer to Module BRR-1).

b) Bearing cups

* Check the bearing cups for rings, scores, chipping, nicks, or erratic wear patterns.
The pinion cups must be solidly seated.
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* Check by attempting to insert a 0,04mm feeler gauge between the cups and the
bottom of their bores.

c) Cone and roller assemblies

* When rotated in the cups, the cone and roller assemblies must turn without any
roughness.
* Examine the roller ends for wear.
Step - wear on the roller ends indicate the bearings did not have enough pre-load or
rollers were slightly cocked.

d) Differential bearing adjusters

* Test the fit of the bearing adjusters in their threads with the bearing caps installed
Fig 54.

* The adjustors should turn easily when the caps are tightened to specifications. Refer
to the workshop manual.
* Check that the faces of the adjusters that contact the bearing cups are smooth and
square.
* Replace the adjustors or examine the threads in the carrier if they do not fit properly.
e) Gears

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* Examine the drive pinion and ring gear teeth for scoring, chips, nicks, or signs of
excessive wear (Fig. 55) on the next page.

The pattern taken during disassembly should be helpful in judging if gears can be re-used.

NB: Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and
flaking are the result of excessive shock loading, or the use of an incorrect lubricant
- scored gears cannot be re-used.

* Examine the teeth and thrust surfaces of the differential gears (Fig. 56).

Wear on the hub of the differential side gears can cause a chuckling noise known as a
chuckle, when the vehicle is operated at low speeds.
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Wear of splines, thrust surfaces or thrust washers can contribute to excessive drive line
back lash.

f) Companion flange

* Ensure that the flat machined surfaces and the bearing cup sockets of the flange
have not been damaged in removing the drive shaft or in removing the flange from
the axle.
* Check that the end of the flange that contacts the oil slinger or pinion front bearing of
flange, is smooth. Refer to Fig. 57.

* Polish this face if necessary.

Roughness aggravates backlash noise, and causes wear on the oil slinger with a
resultant loss in drive pinion bearing pre-load.
* Check that the seal surface is perfectly smooth or leakage will result.

g) Pinion Retainer and Cage Assembly

* Inspect visually for damage.

* Ensure that the bearing and oil seal bores are smooth and not damaged (Fig. 58).

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* Remove any nicks or burrs from the mounting surface.

* Ensure that the pinion bearing cups are seated.
* Examine the bores in the cage assembly carefully if the pinion bearing cups were
removed.
* Clean all lubricant passages.
* Remove any nicks or burrs in these bores to permit proper seating of the cups.

h) Carrier housing

* Inspect visually for damage.

* Ensure that the differential bearing bores are smooth and the threads are not
damaged (Fig. 59).

* Remove any nicks or burrs from the mounting surfaces of the housing.
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* Inspect the housing for sand holes or cracks which could cause lubricant leakage.

i) Differential case

* Ensure that the hubs where the bearings mount are smooth (Fig. 60).

* Check the fit of the differential gears in the counter bores.

* Examine the thrust surfaces carefully.
They are sometimes damaged when the bearing assemblies do not seat firmly on
the hubs, in which case, failure is certain.
* Ensure that the mating surfaces of the two halves of the case and the face of the ring
gear attaching flange are smooth and free from nicks or burrs.

j) Ring gear run out

If the ring gear run out check during disassembly exceed specifications, the condition could
have been caused by warped gear, a distorted or damaged case, or by excessively worn
differential bearings.

To determine the cause of the excessive run out, assemble the differential case without
the ring gear and make the following checks:

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* Mount a dial indicator and then check the face and spigot (pilot) of the ring gear
mounting flange for runout (Fig. 61).

If the runout does not now exceed specifications, install a new ring gear to the case. If the
run out at tighter point is excessive and the gear is true, the condition is due to either the
case of differential side bearings being defective.

* Install new differential side bearings on the case hubs and install the case in the
carrier.
* Check the case run out. If the run out is still excessive, repair or replace the case.

NB: The ring gear and pinion are always matched. Never replace one without the
other.

k) Vent system

* Ensure that the breather hole in the top of the housing is clean, not blocked or
damaged.

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l) Thrust block

* Check that the thrust screw is not bent and that the threads in the casing and lock
nut are not damaged (Fig. 62).
* Ensure that the thrust adjusting screw turns freely in the casing.

m) Planetary gears

* Check the planetary pinion shafts and pinion rollers for scouring, chipping, nicks or
uneven wear patterns.
* Check the gear teeth for scouring, chips, nicks or signs of excessive wear.

Go on to the next page for the practice.

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PRACTICE

Clean all the parts of the differential and final drives, inspect them and complete the condition
report.

LEARNER TRAINING OFFICER

DATE : DATE :

SIGNATURE : SIGNATURE :

REMEMBER ALWAYS WORK SAFE

Once you have passed the entire self-tests

and practices, you are now at liberty to
request a Formative Assessment from your
Assessor.

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