Housings Clean and Inspect
- NOTICE: DO NOT use any
type of motored cleaning device, air tools or drills.
Carefully and thoroughly inspect all drive unit components before assembly.
Thorough inspection of the drive components for wear or stress with subsequent
replacement of worn components eliminates costly drive component repair after
assembly.
- Clean the housings in solvent and remove all sealant material
from the sealing surfaces.
- Inspect the clutch and differential housings for the following:
| • | Damaged sealing surfaces |
| • | Worn or scored bearing race bores |
| • | Damaged bolt, drain plug, or fill plug hole threads |
| • | Damage to the exterior of the housings |
| • | Damaged, restricted or missing vent tube |
| • | Worn mounting bracket bushings |
- Clean and inspect the
vent passage (1) and oil return passage (2).
- Clean and inspect the
vent passage (1) in the rear cover.
- Clean and inspect the drain plug threads (1), and check the welch
plug (2) for leakage, rust holes and looseness.
Gears and Shafts Clean and Inspect
- Clean the gears and shafts
in solvent.
- The ring gear and pinion must be inspected for the proper wear
pattern.
| • | The end of the gear tooth farthest away from the center of the
ring gear (1) is the "heel" end of the tooth. |
| • | The end of the gear tooth nearest the center of the ring gear (2)
is the "toe" end of the tooth. |
| • | The side of the tooth that curves inward or is concave (3)
is considered the "coast" side of the tooth. |
| • | The side of the tooth that curves outward or is convex (4)
is considered the "drive" side of the tooth. |
- Inspect the pinion shaft
for the following:
| • | Worn or damaged splines (1) |
| • | Wear, pitting or discoloration by heat (3) |
| • | Worn or scored shaft (5) |
- Inspect the bearings for a bent bearing cage.
Bearings and Races Clean and Inspect
- Inspect the bearing rollers
and races for the following:
| • | Excessive wear or other damage |
Important: Bearing races with a sign of heat discoloration must be replaced.
- Inspect the bearing rollers and races for heat discoloration. Heat discoloration
ranges from a faint yellow to a dark blue color. This discoloration may result
from an overload or improper lubrication. Excessive heat causes softening
of the rollers and races.
- Inspect the pinion flange sealing surface (1) for wear, damaged
bolt threads (2) and worn or damaged splines (3).
- NOTICE: DO NOT submerge the clutch drum in solvent. This will damage
the friction material and gerotor pump.
Important: The clutch drum is not serviceable, if inoperative conditions are found
replace the unit.
- Wipe with a clean lint free towel and inspect the following:
| • | The pinion nut threads (1) |
| • | The bearing surface (3) |
| • | The front sealing surface (4) |
| • | The rear sealing surface (5) |
- Clean the differential case in solvent.
- Inspect the following for cracking or scoring.
| • | The side bearing mounting surfaces (1) |
| • | The differential pin bores (2) |
| • | The ring gear mounting surfaces (3) |
| • | The side and spider gear thrust washer surfaces (4) |
- Replace the differential carrier assembly as necessary.
- Clean the following parts in solvent.
- Inspect the following for scoring, pitted teeth and cracks.
| • | Side gear thrust washers (1) |
| • | Spider gear thrust washers (3) |
