S1021

X X

REPAIR
D65 MANUAL

X 5/00
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CONTENTS

Description Page
Rear Axle Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Teardown Guideline and Removal of Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Brake Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Axle Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. Planetary Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Axle Bearing and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
G. Differential & Mechanical Differential Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
H. Differential Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I. No-Spin Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
J. Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
K. Specifications, Tightening Torque, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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REAR AXLE DESCRIPTION AND OPERATION

20 21 22 23 24 1 2
3

19 7
18
17 8
16
15 14 13 12 11 10 9

1
1. Rear Axle Center Housing 13. Brake Inner Housing
2. Yoke 14. Brake Actuating Discs
3. Drive Pinion Bearing Retainer 15. Planet Gear Carrier
4. Differential Lock Operating Shaft 16. Rear Axle Shaft
5. Planet Gear 17. Axle Shaft Outer Bearing
6. Sun Gear and Shaft 18. Sleeve
7. Ring Gear 19. Rear Wheel Flange
8. Differential Bearing 20. Axle Shaft Oil Seal
9. Differential Ring Gear 21. Axle Shaft Housing
10. Differential Assembly 22. Axle Shaft Inner Bearing
11. Differential Bearing 23. Brake Discs
12. Differential Lock Assembly 24. Brake Actuating Rod

The rear axle contains the differential, brakes, final

reduction gears, axle shaft, and the differential lock
(Figure 1).

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TORQUE TRANSFER differential action allows virtually all the drive to be

The spiral bevel pinion is held by preloaded opposed applied to this wheel and a little to the opposite rear
tapered roller bearings. The differential ring gear is wheel, which may be on firm ground. The result is
bolted to the differential case, and the drive from the that the unit is either brought to a complete halt or
case is transmitted through a conventional four slowed down considerably.
pinion differential to two side gears of the differential.
When the differential lock is engaged, improved
In each axle housing assembly, a shaft terminates in traction is possible because the lock enables traction
a spur gear, which is the sun gear of the planetary to be obtained from the wheel, which is on firm
reduction gear system. The planetary ring gear is ground, thus enabling the unit to pull through the soft
pressed into the rear axle housing. The three planet ground conditions.
gears are mounted in a carrier and positioned around
Basically, the locking device consists of a dog-type
the sun gear and within the planetary ring gear.
coupling, which is splined to, but free to slide on, the
The planet gears are mounted to the carrier by shafts differential side gear to the differential case. The
and rotate on uncaged needle bearings. The carrier connection side is made through the differential lick
has internal splines that engage splines on the inner adaptor, which has dog teeth on both side faces. The
end of the axle shaft. teeth on the inside engage with teeth on the outside,
with the differential lock coupling.
As the sun gear is driven by the differential, the planet
gears are forced to revolve inside the stationary In operation, pressing of the foot pedal first moves
planetary ring gear and force the carrier to revolve at the coupling into contact with the adaptor and then
a lower speed than the sun gear. compresses the spring in the operating rod assembly
(Figure 2). As the teeth of the coupling come into
The rear shaft is held in opposed tapered roller alignment with the teeth spaced in the fixed adaptor,
bearings, and the play is adjusted by means of the spring tension will move the coupling into
selective spacers held under the retaining bolt. The engagement with the adaptor. The fact that the
shaft terminates in a flange to which the rear wheel spring supplies the final operating force prevents the
is bolted. possibility of damage if excessive force is applied to
the foot pedal.
A common supply of oil is used for lubricating the rear
axle and differential assemblies. The differential ring When full engagement has taken place (noticeable
gear and differential assembly are partly immersed by the reduced pedal pressure), the foot pedal
in oil, which provides adequate lubrication for should be released. The coupling and adaptor teeth
bearing and bushings. side forces, resulting from the transfer of power from
one wheel to another, will keep the coupling and
adapter teeth in mesh. As the drive becomes more
equally distributed, the compressed operating spring
overcomes the reduced teeth side forces and
DIFFERENTIAL LOCK OPERATION
automatically disengages the differential lock.
When one rear wheel of a unit encounters a soft
patch of ground and spins, the normal-type

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6 7 1
5

3 2

Differential Lock Assembly

1. Differential Lock Fork 5. Differential Housing

2. Coupling 6. Spring
3. Adaptor 7. Fork Retaining Bolt
4. Differential Side Gear

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18

Axle Housing Assembly--Exploded View

1. Axle Shaft Outer Bearing 10. Brake Actuating Rod

2. Axle Shaft 11. Brake Actuating Discs
3. Spacer 12. Inner Brake Housing
4. Bearing 13. Rotating Brake Discs
5. Planet Gear Carrier 14. Fixed Brake Discs
6. Retaining Washer 15. Outer Brake Housing
7. Retaining Bolt 16. Ring Gear
8. Lock Plate 17. Axle Housing
9. Sun Gear and Shaft 18. Seal

BRAKE OPERATION Operation of the foot brake pedal causes the rear
The disc brakes consist of two sets of stationary and brake actuating discs to rotate and the balls to rotate
revolving discs. The revolving discs are splined to the up the ramped “pockets.” This rotation expands the
shaft of the sun gear, located on either side of an actuating discs, which force the rear brake disc
actuator assembly (Figure 3). assemblies into contact with the intermediate disc,
the actuating discs, and the inner and outer
The actuator assembly consists of two thrust plates housings. Rotation of the stationary components of
with ramped “pockets” in which steel balls are the brake unit is prevented by a large-diameter
located. The actuating discs are held in contact with torque pin held in the outer brake housing.
the balls by four coil springs and connected by
suitable linkage with the appropriate foot brake
pedal.

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A. TEARDOWN GUIDELINE AND REMOVAL

OF AXLE HOUSING ASSEMBLY
Operations or repairs the can be performed on
counterclockwise (CCW) D65 axle components with
the left and/or right housing assembly removed.

Component Left Axle Right Axle

Brake Overhaul X X
Planetary Overhaul X X
Axle Shaft Bearing/Seals X X
Differential Operating Fork X
Pinion Assembly X
Differential Gears & X
Differential Lock Assembly

1. Drain oil from axle.

2. Place axle in a low stand, and place a jack under
the housing not being removed.
3. Remove brake cylinders, if installed.
4. Install half of the wheel bolts in wheel flange.
5. Remove the right housing assembly first so that
the differential gear set is supported by the left
sun gear when the right housing is removed.
Place a strap around the square section of the
housing next to the bell end (Figure 4).
6. Remove the housing attaching bolts, leaving the
top bolt until last. Use an overhead hoist to 4
remove the housing assembly, and then stand
Rear View of Housing Assembly Removal
the assembly vertically on the wheel disc.
7. Remove the left housing in a similar manner after
the differential assembly is removed.

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B. BRAKE OVERHAUL
1. Right-Hand Axle Housings--Remove the two
bolts securing the differential ring gear thrust
block to the brake housing, and remove the thrust
block.
2. Remove the two nuts and six bolts that retain the
inner disc brake housing assembly in the axle
housing. Lift the brake housing out of the axle
housing.
3. Remove the brake actuator (Figure 5). Remove
the brake rod seal if damaged. To remove the
seal, place a sharp tool between the seal flange
and the rear axle housing, and pry the seal out.
Remove the brake disc assemblies intermediate
discs, and actuating disc assembly. 5
Removing and Installing Brake Actuating Mechanism
4. Lift the sun gear out of the planet gear carrier.
5. Remove the outer brake housing from the axle 1. Actuating Discs
housing. 2. Actuating Link
3. Axle Housing
NOTE: Replace friction plates and separator plates
if they are overheated or worn more than 0.5 mm
(0.020″ ) per friction plate. New thickness is 4.8 mm
(0.0190″ ).

6. Reassemble the brake components in the

reverse order. Be sure the spring is in the groove
on the pullrod boot and the boot is in the groove
on the pullrod.

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C. AXLE BEARING PRELOAD

1. If the planetary gears or the axle bearings or
seals are to be serviced, first check the axle shaft
rolling torque and end play to see if they are
correctly shimmed.
2. Install axle shaft torque tool (see Special Tools,
Section K) as shown in Figure 6. Rolling torque
should be as follows:
• 50 -- 150 in. lb.

3. Check axle shaft end play. If any end play is

detected, use a dial indicator as shown in Figure
7 to determine the amount.
4. If torque is too high, use the next thicker spacer 6
after the planetary or axle system repair.
Axle Shaft Rolling Torque Measurement

5. If 0.003″ or more end play is detected, install a

spacer one size smaller for every 0.004″ or
portion of 0.004″ measured (e.g., if 0.018″ end
play is measure, change to a spacer five sizes
smaller).
6. If this check is not possible before the repair,
install a 0.081″ thick spacer. Position the
selected spacer and shaft retaining washer, and
tighten the axle shaft bolt to 407 N⋅m (300 ft. lb.)
torque. Then, proceed with steps 2 through 5
until bearing preload is okay.
7. To position, the bolt lock may require that the bolt
be tightened more, up to 350 ft. lb. so that the lock
notches will fit the bolt head corners. 7
Axle Shaft End Play Measurement
It may be necessary to turn the bolt lock over.
Apply adhesive or grease to the bottom of the bolt
lock to hold it in position while the side housing
is attached to the center housing.

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D. PLANETARY GEAR ASSEMBLY

1. Remove the axle shaft bolt lock, axle shaft
retaining bolt, axle shaft retaining washer, and
selective spacer
2. Lift the carrier assembly out of the axle housing.
3. If the planetary carrier assembly must be
serviced, bend up one end of the planet gear
shaft retaining ring, and withdraw the ring. Pull
the planet gear shafts from the carrier, and
remove the planet gears, complete with needle
bearings and thrust washers (Figures 8 and 9).
Rebuild the carrier using new components as
required. Pack the needle bearings in the planet
gears with grease, and be sure to bend the ends
of the retainer ring downward. 8
Planet Gear Carrier Assembly

1. Planet Gear Shaft

2. Planet Gear
3. Planet Gear Shaft Retainer

4. If the bearing on the planet gear carrier requires

replacing, removing it by using pulling attach-
ment tool FNH0926 and puller tool FNH09516.
Install a step plate adapter into the end of the
carrier. Install a new cone and roller assembly.
5. If necessary, remove the inner bearing cup from
the housing by using puller FNH09507 and
FNH09567. Install a new cup.

9
Planet Gear Carrier Assembly

1. Retaining Ring
2. Thrust Washer
3. Planet Gear
4. Rollers
5. Thrust Washers
6. Cone and Roller Assembly
7. Carrier
8. Planet Gear Shaft

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6. Inspect the planetary ring gear located in the axle

housing. If damaged or worn. replace as follows:
-- Remove the axle shaft from the axle.
-- Position Tool No. FNH021223 behind the
ring gear and tighten the retaining nuts
(Figure 10).
-- Place the axle housing on a press beam with
the large end down. Insert a bar of suitable
length into the small end of the housing
against Tool No. FNH02123. Position the
other end of the bar under the press ram, and
press out the ring gear.

10
Removing Planetary Ring Gear

1. Tool No. FNH02123

2. Ring Gear

-- Clean the new ring gear and the housing

shoulder, and position the ring gear in the
axle housing, ensuring that the studs in the
housing are aligned with the holes in the ring
gear.
-- Place the axle housing on a press beam with
the large end up. Position Tool No.
FNH02123 on the ring gear (Figure 11), and
press the ring gear into the housing. Be sure
the ring gear is pressed squarely into the
housing.
-- To check that the ring gear is seated correct-
ly, use a feeler gauge to ascertain if there is
a gap between the ring gear and housing 11
shoulder. Installing Planetary Ring Gear
NOTE: If a new planetary ring gear has been
installed in the right-hand axle housing, the 1. Tool No. FNH02123
differential bearing preload must be checked as 2. Ring Gear
described in the Differential Bearing Preload section.

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E. AXLE BEARING AND SEAL REPLACEMENT

1. Starting with the axle in vertical position and the
planetary carrier removed, attach a chain at two
of the bolt holes on the flange of the trumpet
housing.
2. Lift the housing assembly upward approximately
1″, and then place a block of wood on top of the
axle shaft and drive the shaft out of the housing.
3. When removing the axle shaft outer cone and
roller assembly and shaft seal, use tools listed
below Figure 12.

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Axle Shaft Cone and Roller Assembly Removal

1. Ratchet, Tool No. OTC7366

2. Legs, Tool No. FNH09521
3. Pulling Attachment, Tool No. FNH09526
4. Axle Shaft
5. Cone and Roller Assembly
6. Puller, Tool No. FNH09506
7. Shaft Protector, Tool No. FNH09212

4. Use slide hammer, Tool No. FNH09567, and

puller Tool No. FNH09507, to remove the bearing
cup from the outer end of the axle housing
(Figure 13). To replace the cup, use a suitable
stepped plate and a mallet; install cup until fully
seated in housing.

13
Removing Outer Bearing Cup from Axle Housing

1. Tool No. FNH09567

2. Tool No. FNH09507
3. Bearing Cup

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5. Install a new cassette seal by using a metal

sleeve to press on the OD of the seal (Figure 14)
3
6. Install a new bearing by using a suitable sized
sleeve, which can be used as a slide hammer.
7. Using a chain attached to the housing flange,
lower the axle housing over the shaft assembly,
taking care to maintain alignment. Do not change
direction after the seal starts to enter the bore in
the end of the housing or the seal will be
damaged.
8. Measure the removed spacer thickness, and
then use the results obtained in Section C, Axle
Bearing Preload to determine the required 14
spacer thickness. See Specifications in Section
Axle Shaft with Seal and Bearing Installed
K for the available spacers.
9. Assemble the axle shaft retaining bolt and check 1. Cassette Seal
rolling torque and axle shaft end play as 2. Bearing Assembly
described in Section C, Axle Bearing Preload.

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F. PINION ASSEMBLY

15

16

20004159

15

Pinion Shaft Layout

1. Retainer Assembly 9. Bearing

2. Seal 10. Spacer
3. Retainer 11. Bearing
4. Castellated Nut 12. Pinion Shaft
5. Cotter Pin 13. Bearing
6. Washer 14. Lock Ring
7. Seal 15. Seal
8. Yoke 16. Seal Assembly

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Prior to disassembling the drive pinion assembly,

remove the differential from the rear axle center
3
housing.

DISASSEMBLY 4
1. Remove the six bolts and lockwashers securing
the drive pinion assembly to the rear axle center
housing, and using two 9/16″ National Course
(NC) bolts as jacking screws, remove the drive
pinion assembly.
2. Place the drive pinion assembly in a vise.
Remove the cotter pin and the nut by using the
yoke holding tool (See Special Tools in Section 16
K) as shown in Figure 16. 1. Yoke Holding Tool
3. Slide off the yoke, and remove the oil seal 2. Retainer
assembly and O-ring. 3. Pinion
4. Wrench
4. Remove the drive pinion assembly, the bearing
spacer, and the front cone and roller assembly
from the bearing retainer assembly.

INSPECTION AND REPAIR

1. Thoroughly clean and inspect all parts, and if
worn or damaged, install new parts.
2. If it is necessary to install a new rear pinion cone
and roller assembly, the assembly may be
removed as shown in Figure 17. The new cone
and roller are installed by using the tools and a
suitable sleeve shown in Figure 18 to enable the
tool to press on the inner bearing race.
3. It it is necessary to install new retainer bearing
cups, the cups may be removed from the housing
by using Tool No. FNH09507 and FNH09567 or
equivalent. 17
4. If it is necessary to replace the pilot bearing, Removing Drive Pinion Rear Bearing
remove the lock ring from the rear end of the
pinion gear, and pull the pilot bearing off the 1. Tool No. FNH09516
pinion gear and replace it by using appropriate 2. Drive Pinion Shaft
tools. 3. Bearing Assembly
4. Tool No. FNH09190
NOTE: If a new drive pinion is to be installed, a new
differential ring gear must also be fitted. This
installation should be carried out as outlined in
Section G, Differential and Mechanical Differential
Lock Assembly.

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ASSEMBLY
1. Install the pilot bearing on the pinion by using a
suitable hollow sleeve, and fit a new lock ring.
2. Position the pinion shaft assembly in the retainer
assembly.
3. Install the pinion bearing spacer and the front
cone and roller assembly.
4. Place the oil seal O-ring in the groove, and
position the oil seal assembly on the retainer
assembly.
5. Lubricate the outside of splined end of the flange,
and slide the splined end carefully on the pinion 18
shaft splines and through the oil seal assembly Installing Drive Pinion Rear Bearing
until the splined end is stopped by the inner race
of the front bearing cone and roller. 1. Tool No. FNH09516
6. Install the shaft seal, the washer, and the 2. Drive Pinion Shaft
retaining nut. TIghten the nut to 200--600 ft. lb. 3. Sleeve
(271--813 N⋅m). At the same time, align the 4. Rear Bearing Assembly
notches in the nut with the cotter pin hole in the 5. Tool No. FNH09516
pinion shaft.
7. Check the bearing preload with an in-lb torque
wrench as shown in Figure 19. Preload should be
10--40 in. lb. (1.1--4.5 N⋅m). If the rolling torque
check is done in the center housing, leave the
bolts loose.
8. Insert the cotter pin, and bend each half of the pin
over. If the yoke prevents insertion of the cotter
pin in the hold, which aligns with the notches,
remove the yoke and reposition it on the spline.
NOTE: When it is necessary to replace the bearing
retainer, it may be necessary to replace the bearing
spacer to obtain correct preload. In that case, repeat
steps 3 through 7 until the correct preload is
obtained. 19
Measuring Pinion Bearing Rolling Torque

1. Torque Wrench
2. 1-3/4″ Socket

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G. DIFFERENTIAL & MECHANICAL DIFFERENTIAL LOCK ASSEMBLY

20

Differential Assembly

1. Cone and Roller Assembly 9. Retaining Ring

2. Ring Gear and Housing Assembly 10. Washer
3. Side Gear 11. Spring
4. Pinion Gear Assembly 12. Adaptor
5. Side Gear 13. Retaining Bolt
6. Housing 14. Thrust Washer
7. Cone and Roller Assembly 15. Pinion Gear and Washer
8. Coupling 16. Thrust Washer

With the right axle shaft housing removed, withdraw 1. Remove the differential lock ring from the end of
the differential assembly from the center housing. the side gear. WIthdraw the stop washer,
coupling, spring, and adaptor.
DISASSEMBLY 2. Mark the two halves of the differential case to
With reference to Figure 20. facilitate correct installation on reassembly.

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3. Remove the differential cone and roller assembly

from the small half of the case using tools shown
in Figure 21.
4. Extract the differential case retaining bolts.
5. Separate the differential case.
6. Withdraw the thrust washer and side gear, the
spider and pinion assembly, and the second side
gear and washer from the case.
7. Remove the cone and roller assembly in the ring
gear half of the housing by using puller, Tool No.
FNH09516; pulling attachment, Tool No.
FNH09526; and step place adaptor, Tool No.
FNH09210. 21
Removing Differential Bearing
8. Separate the pinion gears from the spider.
1. Tool No. FNH09516
INSPECTION AND REPAIR 2. Tool No. FNH09526
3. Bearing Assembly
1. Clean and inspect all components for damage or 4. Tool No. FNH09210
excessive wear. Install new components where
necessary.
2. If a new differential ring gear is required, drill out
the rivets installed during production, and
replace them with nuts and bolts available from
the Parts department. The bolts should be
tightened to a torque value of 115 N⋅m (85 ft. lb.).
NOTE: If the ring gear is replaced, a new matching
drive pinion must also be installed. Refer to Section
F. Pinion Assembly.

REASSEMBLY
Reassembly of the differential and differential lock
follows the disassembly procedure in reverse. On
reassembly, observe the following requirements:

• Coat all bearing with a suitable wheel bearing

grease prior to installation.
• Tighten the differential case retaining bolts to a
torque of 92--125 N⋅m (68--92 ft. lb.).

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H. DIFFERENTIAL BEARING PRELOAD

Adjust the bearing preload by installing thinner or
thicker shim between the differential cup and the
inner brake housing. Proceed, as follows, to
measure and adjust the differential bearing preload:

1. Install the differential assembly on the inner end

of the left sun gear shaft in the center housing. Do
not install the pinion assembly.
2. Install the right axle housing assembly without
sun gear with four bolts.
3
3. Remove the left axle housing assembly.
4. Push the differential coupling inward to engage
it, and place 1/4″ square stock under the washer
at two locations.
5. Install a sun gear into the differential assembly.
6. Wrap a length of string or electrical wire on
evenly, without overlapping around the sun gear
shaft, and using a pull scale, measure the force
required to rotate the shaft and differential
assembly. Read the scale during rotation of the
shaft. Do not read the scale at the point where
rotation starts. The pull should be 7--34 kg
2
(15--75 lbs.). See Figure 22.
7. If necessary, remove the shim from the inner 1
brake housing in the right axle housing assembly
and install a thicker shim to increase the rolling
torque or a thinner shim to reduce the rolling
torque. 22
Differential Bearing Preload Check
8. See Section K, Specifications, for available
shims. 1. Differential Lock Engaged with Spacers
2. Sun Gear Installed
9. After the rolling torque check, reinstall the left
axle housing assembly, and remove the right 3. Pull Scale
axle housing assembly.

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I. NO-SPIN DIFFERENTIAL ASSEMBLY

1. Install a retaining bolt, washers, and wing nut to
restrain the springs in the no-spin differential
during disassembly (Figure 23).
2. Remove the eight bolts holding the two halves of
the differential case together.
3. Compress the springs on the no-spin assembly,
and remove the wing nut and bolt.
4. Inspect the parts for wear, especially the teeth on
the left-hand and right-hand clutch assemblies
and the spider/cam assembly (Figure 24).

CAUTION
Failure to use a retaining bolt or some other 23
restraining means when separating the differen-
tial case halves can cause injury because
no-spin differentials have compressed springs.

24

No-spin differential spider assembly, clutch assembly, springs, retainers, and side gears.

5. Replace any badly worn parts

6. ALign the gaps in the holdout rings on the left and
right coupling assemblies with the keys on the
sides of the spider assembly.
7. Assemble the springs, retainers, and side gears
to the no-spins center section. Compress the
springs, and assemble the bolt, washers, and
wing nut through the center of the no-spin
assembly.
8. Place the differential case assembly, and install
the eight retaining bolts.
9. Remove the center bolt washers and wing nut.

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J. BRAKE ADJUSTMENT
SPRING APPLY CYLINDER (FAIL SAFE
BRAKE)
1. Assemble cylinder over pullrod.
2. Install bracket and U-bolt assembly with bolts
and tighten.
3. Apply 300 psi hydraulic pressure to pressure port
to compress the spring.
4. Install the conical nut, and tighten to approxi-
mately 1.7 N⋅m (15 in-lb) so that the brake has
locked.
5. Back nut off eight flats.
If the brakes must be adjusted without turning the 25
axle shafts, tighten the conical nut to 5.6 N⋅m (50 Spring Apply--Mico
in-lb) and then back off the nut 2 turns (twelve
flats).
6. Release hydraulic pressure.
7. Install prevailing torque nut, and tighten until it
contacts the conical nut.
8. Apply pressure to port again, and confirm that
axle shaft rotates freely. Install spring and nut
with square head in end of cylinder.
NOTE: Brake cylinders should be filled with mineral
brake fluid (e.g., NH ESN-M6C59-A).

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K. SPECIFICATIONS, TIGHTENING TORQUE, AND SPECIAL TOOLS

AXLE SHAFT PRELOAD
Axle shaft rolling torque using a torque wrench:
• 50 -- 150 in-lb.

AXLE SHAFT PRELOAD

North American Part Number European Part Number Thickness

C5NN-4374-AB 81803491 0.049″ (1.24 mm)
C5NN-4374-L 81803502 0.053″ (1.35 mm)
C5NN-4374-M 81803503 0.057″ (1.45 mm)
C5NN-4374-N 81803504 0.061″ (1.55 mm)
C5NN-4374-R 81803505 0.065″ (1.65 mm)
C5NN-4374-S 81803506 0.069″ (1.75 mm)
C5NN-4374-T 81803507 0.073″ (1.85 mm)
C5NN-4374-U 81803508 0.077″ (1.96 mm)
C5NN-4374-V 81803509 0.081″ (2.06 mm)
C5NN-4374-Y 81803510 0.085″ (2.16 mm)
C5NN-4374-Z 81803511 0.089″ (2.26 mm)

DIFFERENTIAL BEARING PRELOAD

Differential bearing rolling torque using a spring pull gauge: 7--34kgf (15--75 lb).

DIFFERENTIAL BEARING SHIM TABLE

North American Part Number European Part Number Thickness

C5NN-4548-A 81803515 0.038″--0.040″ (0.965--1.018 mm)
C5NN-4548-B 81803516 0.044″--0.046″ (1.118--1.168 mm)
C5NN-4548-C 81803517 0.050″--0.052″ (1.270--1.321 mm)
C5NN-4548-D 81803518 0.056″--0.058″ (1.422--1.473 mm)
C5NN-4548-E 81803519 0.062″--0.064″ (1.575--1.626 mm)
C5NN-4548-F 81803520 0.068″--0.070″ (1.727--1.778 mm)
C5NN-4548-G 81803521 0.074″--0.076″ (1.880--1.930 mm)
C5NN-4548-H 81803522 0.080″--0.082″ (2.032--2.083 mm)

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DRIVE PINION PRELOAD

Drive pinion torque using in-lb torque wrench: 1.1--4.6 N⋅m (10--40 in-lb).

DRIVE PINION SPACER TABLE

North American Part Number European Part Number Thickness

D8NN-4662-FA R, R, R 83914106 1.3281″--1.3286″ (33.734--33.746 mm)
D8NN-4662-GA R, R, B 83914107 1.3289″--1.3294″ (33.754--33.767 mm)
D8NN-4662-HA R, R, Y 83914108 1.3297″--1.3302″ (33.774--33.787 mm)
D8NN-4662-JA R, R, W 83914109 1.3305″--1.3310″ (33.795--33.807 mm)
D8NN-4662-KA B, B, B 83914110 1.3313″--1.3318″ (33.815--33.828 mm)
D8NN-4662-LA B, B, Y 83914111 1.3321″--1.3326″ (33.835--33.848 mm)
D8NN-4662-MA B, B, W 83914112 1.3329″--1.3334″ (33.856--33.868 mm)
D8NN-4662-NA Y, Y, R 83914113 1.3337″--1.3342″ (33.876--33.889 mm)
D8NN-4662-PA Y, Y, B 83914114 1.3345″--1.3350″ (33.896--33.909 mm)
D8NN-4662-SA Y, Y, Y 83914115 1.3353″--1.3358″ (33.917--33.929 mm)
D8NN-4662-TA W, W, R 83914116 1.3361″--1.3366″ (33.937--33.950 mm)
D8NN-4662-UA W, W, B 83914117 1.3369″--1.3374″ (33.957--33.970 mm)
D8NN-4662-VA W, W, Y 83914119 1.3377″--1.3382″ (33.978--33.990 mm)
D8NN-4662-XA W, W, W 83914120 1.3385″--1.3390″ (33.998--33.011 mm)

Color Code: R--Red, B--Blue, Y--Yellow, W--White

TIGHTENING TORQUE

Components ft-lb N⋅⋅m

Axle shaft housing retaining bolts 140--170 190--230
Axle shaft retaining bolt 300--350 407--475
Differential ring gear retaining nuts 85 115
Differential case retaining bolts 68--92 92--125
Differential lock fork pivot shaft retaining bolt 24--30 32--41
Inner brake housing retaining bolts 80--95 108--129
Inner brake housing retaining nuts 80--95 108--129
Drive pinion bearing retaining bolts 100--125 135--170
Drive pinion nut 200--600 271--813
Ring gear thrust block 27--37 37--50

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SPECIAL TOOLS

Description Tool No. Ref. Section

Axle shaft torque tool * C
Pusher-puller bearing cup pulling attachment FNH09507 E, D
Puller bearing tool (slide hammer) FNH09567 E, D
Pusher-puller bearing pulling attachment (large) FNH09526 E, D, G
17-1/2 ton capacity pusher-puller tool FNH09506 E
Pusher-puller legs attachment FNH09521 E
Pusher-puller ratchet attachment OTC7366 E
Pusher-pull shaft protectors (set of 6) FNH09212 E
Yoke holding tool * F
Puller Tool FNH09516 F, G, D
Pusher-puller bearing pulling attachment (small) FNH09190 F
Pusher-puller tool to remove--install ring gear FNH02123 D
Step plates (set of 11) FNH09210 G

*See specifications for making tools on page 24.

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26
Axle Shaft Torque Tool

Make a yoke holding tool (1410 flange) according to

the following dimensions:

1. 1.65″ (42 mm)

2. 2.559″ (65 mm)
3. 0.394″ (10 mm)
4. 1.575″ (40 mm)
5. 8.66″ (220 mm)
6. 5.51″ (140 mm)
7. 3.74″ (95 mm)
8. 0.394″ (10 mm)
27
9. 4.33″ (110 mm) Yoke Holding Tool

24