Front Axle - Disassembly

DISASSEMBLY

Special Tools:









Figure 1 - 175MM FIA Front Axle Exploded View









1. Remove pinion housing assembly bolts (1).





2. Remove pinion housing assembly (4)(Figure 3).





3. Remove pinion depth shim (1).





4. Measure pinion housing assembly rotating torque (1). Rotating torque should be 130-250 Nm (12-22 in. lbs.). If rotating torque is outside of this range, bearing replacement is required. Refer to Pinion Housing Disassembly.





5. Remove pinion flange nut (1)(Figure 6).





6. Using puller (1)(Figure 7), pull pinion flange from shaft.





7. Remove pinion flange (1)(Figure 8).





8. Using suitable tool, remove pinion seal (1).





9. Remove pinion housing O-ring seal (1).





10. Measure differential rotating torque with Torque Tool C-4995A. Rotating torque should be within 190-250 Nm (17-22 in. lbs). Measurements recorded out of this range require differential side bearing replacement and/or side bearing preload adjustment.





11. Remove axle housing cover (5). Remove differential assembly (3) and inboard axle seal (2).





12. Remove axle housing cover o-ring (1).

PINION HOUSING DISASSEMBLY





1. Press pinion gear/shaft (2) out of housing. Use suitable adapter (1) to protect end of shaft.





2. Remove pinion bearing (1)(Figure 15).





3. Remove pinion bearing spacer (1)(Figure 16).




Using splitter or equivalent (2)(Figure 17), press off pinion head bearing (1).





4. Using a suitable punch, remove pinion tail bearing cup (1)(Figure 18).





5. Using suitable punch, remove pinion head bearing cup (1)(Figure 19).

DIFFERENTIAL DISASSEMBLY

NOTE: The differential ring gear is welded to the differential case and is not serviceable separately.





1. Rotate differential side gears about case and remove side gears (2)(Figure 20) and thrust washers (1).





2. Using suitable punch, drive pinion shaft roll pin (1) into case until it bottoms.
3. Drive old roll pin from shaft and discard old pin.





4. Remove pinion shaft (1), pinion gears (3) and thrust washers (2). Drive out and discard pinion shaft roll pin.





5. Using Plug (1) and Bearing Splitter (3), press differential side bearing (2) off of ring gear side and discard.





6. Using Plug (1) and Bearing Splitter (3), press differential side bearing (2) off of opposite side and discard.

AXLE HOUSING





1. Remove differential side bearing cup from axle housing cover. Install Bearing Remover (1).





2. Remove differential side bearing cup with Bearing Remover (1).






NOTE: Side bearing preload shims affect adjust differential bearing preload and ring gear backlash and must not be mixed up. Measure and tag side bearing preload shims upon removal.

3. Remove side bearing preload shim (1).





4. Measure preload shim (1) to identify for replacement.





5. Using Remover (1) and Slide Hammer (2), remove and discard inboard differential side bearing cup.





6. Remove side bearing preload shim from housing (1).





7. Measure preload shim (1) to identify for replacement or installation.