Front Axle - Assembly

ASSEMBLY

Special Tools:













Figure 1 - 175MM FIA Front Axle Exploded View





DIFFERENTIAL/RING GEAR ASSEMBLY





1. Install pinion shaft (1)(Figure 2), pinion gears (3) and thrust washers (2).





2. Using suitable punch, install new roll pin and install flush to differential case (1).





3. Install differential side gears (2) and thrust washers (1). Rotate into position.





4. Using Installer (1), install new differential side bearing (ring gear side).





5. Using Installer (1), install new differential side bearing (opposite side).

PINION HOUSING ASSEMBLY





1. Using Handle (2) and Installer (1), press new pinion head bearing cup (3) into pinion gear housing.





2. Using Handle (1) and Installer (2), press new pinion tail bearing cup into pinion gear housing.





3. Using Installer , install new pinion head bearing.





4. Install pinion bearing select spacer (1) removed upon disassembly. Spacer thickness will be measured/verified at end of assembly.





5. Install pinion gear/bearing assembly into pinion housing. Using Installer (1) , press new pinion tail bearing (2) onto shaft.





6. Using Installer (1), install new pinion seal.





7. Using Installer (1), install pinion flange (2) until it bottoms.





8. Using Spanner Wrench (2)(Figure 14), install pinion flange nut and torque to 475 Nm (350 ft. lbs.).





9. Measure pinion housing assembly rotating torque (1). Rotating torque should be within 130-260 Nm (12-23 in. lbs.).





10. If rotating torque is lower than this range, disassemble pinion housing, measure and install a slightly thinner spacer (1), reassemble and reverify. If rotating torque is higher than this range, disassemble pinion housing, install a slightly thicker spacer, reassemble and reverify rotating torque.
11. Select the pinion depth shim required for this axle assembly. Pinion Depth

AXLE HOUSING ASSEMBLY





1. Using Installer (1)(Figure 17), install new axle seal (inner) (2) into housing.





2. Install side bearing preload shim (2) into axle housing (1).





3. Using Handle (4) and Installer (3) press new side bearing cup (2) into housing (1) until it bottoms.





4. Install differential side bearing preload shim (1) into axle housing cover (2).





5. Using Handle and Installer (1), press new side bearing cup into cover until it bottoms. Use suitable cup (3) to support and protect cover.





6. Install differential/ring gear assembly (3), new cover o-ring seal (4), and cover (5).
7. Install and torque cover-to-housing bolts to:
- M10x40 - 65 Nm (48 ft. lbs.)
- M8x25 - 34 Nm (25 ft. lbs.)





8. Using Torque Tool (1), measure differential side bearing rotating torque (preload). Rotating torque should be within 190-250 Nm (17-22 in. lbs.).





9. If rotating torque is below this range, disassemble housing, measure and install slightly thicker preload shims (1). Add thickness equally to both sides. If rotating torque is above this range, disassemble housing, measure and install slightly thinner preload shims. Remove thickness equally from both sides.





10. Install new pinion housing o-ring seal (1)(Figure 25).





11. Install pinion housing assembly into axle housing with proper pinion depth shim (1)(Figure 26). Pinion Depth





12. Install and torque pinion housing-to-axle housing bolts (1) to 34 Nm (25 ft. lbs.)
13. Measure and adjust ring gear backlash. Backlash should be within 0.05-0.11mm (0.002-0.004 in.). Measuring Backlash