Cebdg65194 701 840

G-01 .
I 5K
FRONT AXLE ASSEMBLY

APPLICABLE MODELS SERIAL NUMBERS
GD530A-1 200417 & Up

GD530AW-1 200417 & Up
GD650A-1 200417 & Up
GD650AW-1 200417 & Up
GD670A-1 200417 & Up
GD670AW-1 200417 & Up
CAUTION
ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING
DISASSEMBLY AND REASSEMBLY.
ALL JACKING HOISTING AND GENERAL WORKSHOP

EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE
IN GOOD WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

INJURY.
SAFE WORKSHOP PRACTICES ARE A MUST.
FOR TABLE OF CONTENTS SEE PAGE 1
KOMATSU DRESSER COMPANY 850 SOUTH STREET GALION, OHIO 44833
0194
GENERAL TORQUE VALUES
Refer to the “General Torque Values” shop manual section when SPECIFIC TORQUES are not given in the this
shop manual section. All values listed throughout this manual are lubricated (WET) unless stated otherwise.
METRIC CONVERSIONS
Refer to “Metric Conversions” shop manual section for metric conversion of U.S. Measurements.
SHOP MANUAL SECTION G-01.15K
TABLE OF CONTENTS
CONTENTS PAGE
DESCRIPTION ................................................ . 2
FRONT AXLE TORQUE VALUES .................................. . 6
TESTSANDADJUSTMENTS ..................................... . 8
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT ...... . 8
SERVICING .................................................. . 11
REMOVAL ................................................ . 11
DISASSEMBLY ............................................. . 14
CLEANING AND INSPECTION ................................. . 20
REASSEMBLY ............................................. . 22
INSTALLATION ............................................. . 29
1
DESCRIPTION
The basic design of the front axle assembly is common to both Non-All Wheel
Drive and All Wheel Drive graders.
The only major difference is the axle spindle assembly area. Steering cylinders,
leaning wheel cylinder, tie rod, etc.
are assembled in the same manner. The following two exploded views shows
the two axle assemblies and related
components.
3gure 1 EXPLODED VIEW OF NON-ALL WHEEL DRIVE FRONT AXLE ASSEMBLY
2
LEGEND FOR NON-ALL WHEEL DRIVE FRONT AXLE
The exploded view shown on the previous page and legend show here are to help identify parts and their
orientation to each other while servicing the Non-All Wheel Drive Front Axle Assembly. Some components
mentioned during service procedure may only be shown in this illustration.
1. FRONT AXLE WELDMENT 33. FLAT WASHER

2. STEERING CYLINDER (SEE APPROPRIATE 34. FLAT WASHER
SHOP MANUAL SECTION FOR SERVICING) 35. LEANING WHEEL PIN
3. LEANING WHEEL CYLINDER (SEE 36. PIN
APPROPRIATE SHOP MANUAL SECTION FOR 37. COTTER PIN
SERVICING) 38. TIE ROD
4. GREASE FITTING - 45” 39. HEX NUT
5. SPINDLE WELDMENT - R.H. 40. SOCKET ASSEMBLY - R.H.
6. SPINDLE WELDMENT - L.H. 41. SLOTTED NUT
7. LEANING WHEEL ROD ASSEMBLY & BALL 42. SOCKET ASSEMBLY - L.H. & SLOTTED NUT
BUSHING 43. COTTER PIN & FLAT WASHER
8. GREASE FITTING 44. GREASE FITTING
9. AXLE PIVOT SHAFT 45. HEX NUT
10 GREASE FITTING 46. STUD
11: RETAINING RING 47. SPACER
12. COVER PLATE 48. LOCK NUT
13. BUSHING 49. COLLAR
14. THRUST WASHER 50. SEAL
15. PIN & ROLL PIN 51. BEARING CONE
16. PIN 52. BEARING CUP
17. STEERING YOKE - R.H. 53. WHEEL
18. STEERING YOKE - L.H. 54. BEARING CUP
19. LOCK NUT 55. BEARING CONE
20. FLAT WASHER 56. SHIM - 0.005 In. (0.127 mm)
21. THRUST BEARING SHIM - 0.015 In. (0.381 mm)
22. O-RING 57. RETAINER
23. SEAL RETAINER 58. BOLT
24. SPACER 59. GASKET
25. BUSHING 60. HUB CAP
26. O-RING 61. BOLT
27. BUSHING 62. LOCK NUT
28. PIVOT PIN 63. BOLT
29. GASKET 64. RIM CLAMP
30. COVER 65. HEX NUT
31. BOLT
32. LOCK WASHER
15358
L
F igure 2 EXPLODED VIEW OF ALL WHEEL DRIVE FRONT AXLE ASSEMBLY
4
LEGEND FOR ALL WHEEL DRIVE FRONT AXLE
The exploded view shown on the previous page and legend show here are to help identify parts and their
orientation to each other while servicing the All Wheel Drive Front Axle Assembly. Some components mentioned
during service procedure may only be shown in this illustration.
1. GEARBOX - L.H. (SEE APPROPRIATE SHOP 29. BUSHING

MANUAL SECTION FOR SERVICING) 30. PIVOT PIN
2. HOSE GUARD 31. O-RING
3. HOSE GUARD 32. BUSHING
4. LEANING WHEEL ROD ASSEMBLY & BALL 33. GASKET
BUSHING 34. COVER
6. FRONT AXLE WELDMENT 35. BOLT & LOCK WASHER
7. STUD 36. STEERING YOKE - R.H. & STEERING YOKE -
8. THRUST WASHER L.H.
9. PIN 37. ROLL PIN
10. AXLE PIVOT SHAFT 38. PIN
11. BUSHING 39 TIE ROD
12. COVER PLATE 40 HEX NUT
13. RETAINING RING 41 SOCKET - R.H.
14. GREASE FITTING 42 SLOTTED NUT & COTTER PIN
15. PIN & COTTER PIN 43 FLAT WASHER
16. GREASE FITTING - 45” 44 GREASE FITTING
17. LEANING WHEEL CYLINDER (SEE 45. SOCKET - L.H. & SLOTTED NUT & COTTER
APPROPRIATE SHOP MANUAL SECTION FOR PIN
SERVICING) 46. GEARBOX - R.H. (SEE APPROPRIATE SHOP
18. GREASE FITTING MANUAL SECTION FOR SERVICING)
19. LOCK NUT 47. VALVE EXTENSION
20. FLAT WASHER 48. RIBBED NECK BOLT
21. LEANING WHEEL PIN 49. RIM CLAMP
22. FLAT WASHER 50. HEX NUT
23. BOLT - WELDED TO YOKE 51. STEERING CYLINDER (SEE APPROPRIATE
24. FLAT WASHER SHOP MANUAL SECTION FOR SERVICING)
25. O-RING 52. SPACER
26. THRUST BEARING 53. LOCK NUT
27. SEAL RETAINER 54. HEX NUT - L.H.
28. SPACER __.
55 U-BOLT
FRONT AXLE TORQUE VALUES
is a comprehensive listing of special torques used during overhaul of this component.

The following
RIM TO WHEEL NUTS

NON-AWD FRONT AXLE
(8) 5/8”-11 GRADE 5
115 Ibf ft (15.9 kg*m)
AWD FRONT AXLE
(12) 5/8”-11 GRADE 5
1 IO Ibf ft (15.2 kg*m)
Figure 3
FRONT AXLE TO FRAME PIVOT PIN CAPS

FOUR BOLT PIVOT CAPS
(8) 3/4”-IO GRADE 8
280 Ibf ft (38.7 kg*m)
I 15941A 1
Figure 4
TIE ROD
(NON-AWD & AWD FRONT AXLES)
(2) 7/8”-14 GRADE 2
170 Ibf ft (23.5 kg*m)
Figure 5
6
STEERING CYLINDERS
(NON-AWD & AWD FRONT AXLE)
ROD END
(2) 7/8”-14 GRADE 2
170 Ibf ft (23.5 kg*m)
BASE END
(2) 7/8”-14 LIGHT THIN
129 Ibf ft (17.8 kg*m)
?gure 6
STEERING YOKE TO AXLE

(NON-AWD & AWD FRONT AXLES)
(2) l-3/8”-12 LIGHT THIN
494 Ibf ft (68.3 kg*m)
Figure 7
LEANING WHEEL CYLINDER &TIE BAR

(NON-AWD & AWD FRONT AXLE)
(3) l-3/8”-12 LIGHT THIN
494 Ibf ft (68.3 kg*m)
Figure 6
7
TESTS AND ADJUSTMENTS
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT
START POINT
The steering cylinders control how far the spindle assemblies are allowed to move. This movement in turn controls
the turning radius of the grader. The steering cylinders must be adjusted this way to obtain a proper turning radius
in both directions.
1. Steering cylinders to be equal length.
A. Factory production set at 24.000 In. (609.600 mm)

overall retracted
All Wheel Drive, print # 158206
Non-All Wheel Drive, print # 157537
B. Field check - measurement from hex end of

steering cylinder piston rod behind lock nut to
center of grease fitting on ball socket assembly
must be 3.562 In. (90.475 mm).
1) Loosen jam nut (I, Figure 9) on ball socket

assembly (2).
2) The steering cylinder ball socket assembly (with Figure g

jam nut installed) must be adjusted in the end
of the piston rod (3) until 3.562 In. (90.475 mm) can be measured from end of piston rod to center of
grease fitting on ball socket assembly, as shown in, Figure 9. This can be done by turning the piston
rod.
3) Once the 3.562 In. (90.475 mm) adjustment is made, tighten the jam nut.
4) Repeat Steps 1 .B.l) thru 1 .B.3), for other steering cylinder.
PROCEDURE
1. Park grader on a “LEVEL” concrete surface. Make sure

that the front tires are properly inflated to the same PSI.
Tires must be the same brand and size.
2. Using steering wheel and leaning wheel cylinder control

lever, position front wheels to that they are in the
straight ahead position and that the camber angle “X”
(Figure 10) is the same on both sides.
Figure 10
8
3. Check and adjust front wheel “Toe In,” if necessary.
All Wheel Drive - 0.0 In. (0.000 mm) I_- FRONT _I

Non-All Wheel Drive - 0.125 In. (3.175 mm)
A. Measure the distance between the wheels of the

grader on the same horizontal centerline as the
spindle axle. These measurements must be taken
at both the front and rear of the wheels (Figure 11).
NOTE: Do not measure on tires or tire rims. Due to

variances in tires, inaccurate measure-
k- REAR -1
ments can result.
B. NON-ALL WHEEL DRIVE AXLE ONLY: The 15359

measurement at the rear of the wheels should be ‘igure 11
approximately l/8” (0.12” &0.03”)
(3.048 f0.762 mm) more than the front. If not, the tie rod will have to be adjusted to obtain proper toe-in.
C. ALL WHEEL DRIVE AXLE ONLY: On All Wheel Drive (AWD) front axles, there MUST BE ZERO TOE-IN.
Front and rear measurements MUST EQUAL.
D. If front wheels need alignment, loosen jam nut (1,

Figure 12) on both ends of the tie rod (2), at the
ball socket assembly (3).
E. The tie rod has R.H. threads on the R.H. end, and
L.H. threads on the L.H. end. This thread
combination allows the wheel alignment to be
adjusted by turning the tie rod.
F. Once the proper alignment is obtained, tighten the

jam nuts (1).
15729
‘igure 12
4. Synchronize steering cylinders:
A. Disconnect L.H. steering

cylinder ball stud assembly
r MATCH MARK
7
from L.H. steering arm.
B. Steer machine right so rod

end of disconnected L.H.
steering cylinder is extended
and both steering cylinders
are being bottomed by
hydraulic pressure.
C. Match mark rod end of L.H. EXAMPLE:

steering cylinder and ball stud
assembly, so that the number L.H. CYLINDER R.H. CYLINDER
of adjustment turns can be
3 TURNS TO SEAT. 1 - l/2 TURNS FOR
counted.
FINAL ADJUSTMENT.
D. With steering pressure holding
both cylinders bottomed,
adjust L.H. steering cylinder
ball stud, “IN” or “OUT” to
seat it fully in steering arm. DIVIDE BY TWO.
NOTE: Very carefully count

the number of full and 1 - l/2 TURNS FOR
partial turns. FINAL ADJUSTMENT.
NOTE: Record the direction

(,,,’ or “OLJY) of
ball stud turns.
E. Divide number of turns above

15935
by 2.
FigWe 13
NOTE: The result is the

amount of turns both steering cylinders must be adjusted from their “ORIGINAL POSITION.”
Direction of turns (“IN” or “‘OLJrl) from “ORIGINAL POSITION” for each cylinder is the same, as
required to seat ball stud in steering arm in Step 4.0 above.
F. Reset L.H. ball stud at l/2 amount of turns moved in Step 4.D, and re-assemble in steering arm.
G. Match mark rod end of R.H. steering cylinder and ball stud assembly, so that the number of adjustment
turns can be counted.
H. On R.H. steering cylinder, loosen ball stud to steering cylinder rod lock nut and adjust ball stud position by
turning cylinder rod the number of turns calculated in Step 4.E above.
NOTE: Make sure that direction piston rod is turned results in correct direction of ball stud movement
noted at Step 4.0.
5. Re-tighten all lock nuts.
10
6. Measure from grease fitting to piston rod end on both cylinders to ensure measurements are equal. This
measurement may vary from the initial 3.562 In. (90.475 mm) setting.
7. Secure the R.H. and L.H. ball stud assemblies into position. Install plain washer and slotted nut to 170 Ibf ft
(23.5 kgam). If necessary, increase torque on nut to install cotter pin.
SERVICING
The following is only one method of obtaining a removal, disassembly, cleaning and inspection, reassembly, and
installation of the front axle assembly.
Thoroughly clean the component to be serviced and the surrounding area. This will help prevent contamination from
entering the component or system being serviced.
REMOVAL
1. Remove grease zerk (I, Figure 14) from bottom of

drawbar ball joint socket (2).
Figure 14
2. Remove both ends of tie rod assembly (1, Figure 15) by

removing cotter pin (2), slotted nut (3) and flat washer.
Move tie rod assembly out of work area.
NOTE: On some axle assemblies, there may not be a

flat washer under the slotted nut.
Figure 15
11
3. With the parking brake set, raise the front tires clear of
the ground, with the moldboard of the machine.
4. Have another person position suitable blocking (1,

Figure 16) under the drawbar ball joint (2) and relieve
tension on hydraulic lift cylinders.
A WARNING! Use extreme care

placing blocking under frame.
when
Figure 16
5. Remove four lug nuts (1, Figure 17) rim clamps (2) and
front tires on each side of the axle assembly.
Figure 17
6. Tag and match mark hoses (1, Figure 18) to steering

cylinders (2). Remove and cap fittings and hoses.
Figure 16
12
7. Tag and match mark hoses (1, Figure 19) to leaning

wheel cylinder (2). Remove and cap fittings and hoses.
A
WARNING! Front axle wheels may lean
to one side when hoses are
disconnected from cylinder.
8. ALL WHEEL DRIVE AXLE ONLY: Refer to

approximately Shop Manual Section for the All Wheel
Drive Gearbox Assembly. This manual will show
additional hoses and sensors that must be tagged and
disconnected prior to removal of axle assembly from
unit. Figure 19
9. Using a suitable lifting device, sling axle assembly (1,

Figure 20).
Figure 20
10. Remove eight bolts with flat washers (1, Figure 21) and
two pivot caps (2).
NOTE: When removing rearpivot cap, remove locating

pin (not shown).
11. Lower axle assembly and remove from machine. Place

on a work bench and/or table and prepare for
disassembly.
15350A
Figure 21
13
6. Remove self-locking nut (1, Figure 25) and flat washer

(2), mounting leaning wheel cylinder (3) to steering yoke
(4).
7. Supported by sling and overhead hoist, remove self-

locking nut (5, Figure 25), flat washer (6) rod assembly
(7) and flat washer (8). Support opposite side of spindle
assembly when removing rod.
8. Press ball bushing out of each end of rod (7,

Figure 25), if replacement is necessary.
Figure 25
9. Remove cotter pin (1, Figure 26), pin (2) and leaning
wheel cylinder (3). Remove base end from mounts, then
rod end.
NOTE: Refer to appropriate Shop Manual Section for

servicing leaning wheel cylinder.
Figure 26
10. Remove cotter pin (1, Figure 27), slotted nut (2), flat
washer and steering cylinder socket assembly (3) from
spindle weldment.
NOTE: On some axle assemblies, there may not be a

flat washer under the slotted nut.
Figure 27
15
11. Remove grease zerk (1, Figure 28), retaining ring (2)
and cover plate (3) from top and bottom of steering
yoke.
12. It should not be necessary to disassemble this area

further, unless two thrust washers (4, Figure 29) are to
be replaced.
NOTE: There is a roll pin (1) installed through the top

spindle pin hole, which can be tapped, with a
drift punch into pin (2) of spindle weldment.
This pin is 0.375 In. (9.525 mm) diameter.
13. Drive pin (2, Figure 29) out of steering yoke and spindle
weldment (3). Once pin (2) is removed drive roll pin (1)
out of it.
NOTE: Do not damage tapped hole for grease fitting in

pin (2).
NOTE: Support spindle in order to prevent injury when

pin has fallen from spindle assembly.
14. Remove spindle weldment and two thrust washers (4, Figure 29), top and bottom.
15. Remove bushings (not shown) from steering yoke, if replacement is necessary.
NOTE: When removing bushing pay attention to which side of the bushing is worn so that when new bushing
is installed the split can be located properly.
16
16. Remove four bolts and lock washers (1, Figure 30),
cover (2) and gasket.
Figure 30
17. Support yoke (8, Figure 31) with overhead hoist and
strap.
18. Remove self-locking nut (1, Figure 31) and flat washer
(2). Drive pivot pin (6) from yoke, removing two seal
retainers (3), two thrust bearings (4) and two O-rings
(5).
NOTE: Insert shows how stack-up is to be removed
from rear axle weldment arm.
NOTE: A O-ring (not shown) is located on the pivot pin,

seated in the inside of the front arm bushing.
See cross section Figure 32.
19. Press leaning wheel pin (7, Figure 31) out of yoke (8), Figure 31
if replacement is necessary.
NOTE: Leaning wheel pin is tapered. Be sure to press on small end.
17
r BUSHING
,
FLAT WASHER
LOCK
15360
Figure 32 CROSS SECTION OF STEERING YOKE PIVOT PIN ASSEMBLY
20. Remove two bushings (1, Figure 33), one form each
arm, and one spacer (2) from rear axle weldment arm.
NOTE: Spacer (2) sets inside bore of bushing.
NOTE: When removing bushing pay attention to which

side of the bushing is worn so that when new
bushing is installed the split can be located
properly.
Figure 33
18
21. Tag and remove hoses (1, Figure 34) from steering
cylinders (2). Remove lock nut (3), stud (4) and two
spacers (5) from base end of each steering cylinder.
Remove steering cylinders.
NOTE: Refer to cross section shown in Figure 35.
22. Remove two retaining rings (6, Figure 34), grease zerks
(7) and cover plates (8).
23. Drive pivot pin (9, Figure 34) from weldment (IO),
remove two thrust washers (11).
NOTE: Do not damage grease zerk tapped hole in

pivot pin.
Figure 34
24. Remove two bushings (not shown) from axle weldment,
NOTE: When removing bushing pay attention to which side of the bushing is worn so that when new bushing
is installed the split can be located properly.
COVER PLATE
I-
/, /r
/- GREASE FllTlNG
RETAINER RING
BUSHING
,- THRUST WASHER
15361
Figure 35 CROSS SECTION OF FRONT END OF PIVOT PIN ASSEMBLY
19
CLEANING AND INSPECTION
Some of the following information may not apply to the particular component
that you are servicing.
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign
material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as
thrust bearing, matched parts, etc.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved
and parts are thoroughly clean.
A WARNING! Care should be exercised to avoid inhalation

creating fire hazards when using solvent type cleaners.
of vapors, exposure to skin and
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then remove
bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly
clean. To dry bearings, use moisture-free compressed air. Be careful to direct air stream across bearing to
avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING; bearings may be
rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing mating cup or cone at the same time. After
inspection, dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them until
installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective bearing
housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of
any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal
casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals.
If this happens, that portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
20
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye. Examine
teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks
or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that are deeply
grooved or scratched which would affect their operation.
21
REASSEMBLY
1. Lubricate and install two new bushings in axle

weldment.
NOTE: install bushings with split at 45” to horizontal

and vertical centerlines. Split should be located
on non-load carrying side of bushing.
NOTE: Refer to Figure 37 for cross section of pivot pin

assembly.
2. Start pivot pin (9, Figure 36) through axle weldment (10)
and position two new thrust washers (11) over pin. The
lips of these two seals must face each other toward the
inside of axle weldment.
NOTE: When installing pivot pin make sure that Figure 36

locating hole (for locating pin) is positioned on
the bottom side. This hole must align with hole in rear retainer cap.
3. Once the pin is driven into both front and rear bores of axle weldment, install front and rear cover plates (8,
Figure 36). Install retaining rings (6) and grease zerks (7).
4. Position steering cylinders (2, Figure 36) in place. Install spacers (5), studs (4), and lock nuts (3). Tighten lock
nuts as specified in “Front Axle Torque Values” section of this manual.
5. Install hoses (1, Figure 36) and tighten fittings as tagged during removal.
COVER PLATE
/- /- GREASE FllTlNG
RETAINER RING
BUSHING
THRUST WASHER
- PIN
15361
Figure 37 CROSS SECTION OF FRONT END OF PIVOT PIN ASSEMBLY
22
6. Lubricate and install two new bushings (1, Figure 38),

one in each axle weldment arm.
7. Install one spacer (2, Figure 38) in rear arm only.
NOTE: install bushings with split at 45” to horizontal

8. Press leaning wheel pin (7, Figure 39) into yoke (8).
9. Start pivot pin (6, Figure 39) through arm and yoke.
Seat O-ring (not shown) on inside of front arm bushing.
See cross section Figure 40. Position O-ring (5), thrust
bearing (4) and seal retainer (3) on pivot pin as shown
by insert.
NOTE: Seal retainer lip goes toward arm, on both

sides.
10. Install flat washer (2, Figure 39) and self-locking nut (1).
Tighten nut to seat pin against taper.
BUSHING
-/-
I I
FIAT WASHER
LOCK
Y-L
RETAINER
L LBUSHING
O-RING
O-RING
15360
7gure 40 CROSS SECTION OF STEERING YOKE PIVOT PIN ASSEMBLY
23
11. Install cover and new gasket (2, Figure 41), four bolts
and lock washers (1).
Figure 41
12. Lubricate and install two new bushings (not shown) in

steering yoke.
NOTE: Install bushings with split at 45” to horizontal

13. Position two thrust washers (4, Figure 42) (one on top
and one on bottom of spindle) and spindle weldment (3)
in steering yoke.
NOTE: Support spindle adequately to prevent injury

which may occur.
14. Align holes between thrust washers, spindle and

steering yoke. Drive center pin (2, Figure 42) in, until Figure 42
roll pin hole in pin aligns with roll pin hole in spindle.
Install roll pin (1) until flush with yoke.
15. Install cover plate (3, Figure 43), retaining ring (2) and
grease zerk (1) in top and bottom of steering yoke.
Figure 43
24
16. Install steering cylinder socket assembly (3, Figure 44)

through hole in spindle weldment.
17. Install flat washer and slotted nut (2, Figure 44). Tighten
slotted nut to 170 Ibf ft (23.5 kg*m). If necessary,
increase torque on nut to install cotter pin (1).
NOTE: A f/at washer must be used under the slotted

nut. Install a flat washer if one was not present
at disassembly.
Figure 44
18. Install leaning wheel cylinder (3, Figure 45) rod end
first, then base end.
19. Install pin (2, Figure 45) and cotter pin (1) to secure
base end of cylinder in position.
Figure 45
20. Press ball bushing in each end of rod (7, Figure 46).
21. Install flat washer (8, Figure 46), rod assembly (7), flat
washer (6) and self-locking nut (5) onto steering yoke
(4).
22. Install flat washer (2, Figure 46) and self-locking nut (1)
mounting leaning wheel cylinder rod end (3) to steering
yoke.
Figure 46
25
23. NON-ALL WHEEL DRIVE AXLE ONLY: Hand pack bearings (1 and
3, Figure 47) with grease.
NOTE: For proper grease specifications refer to Operator’s Manual

for your unit.
24. Install collar (5, Figure 47) onto spindle (6). Collar must be seated
against shoulder. Install seal (4) onto collar (5) as shown. Note
direction of seal lip. Bearing (1) cone must go on spindle and cup
must be in wheel (2). Bearing (3) cup must be installed in wheel (2)
but cone should be installed after wheel (2) is placed on spindle
(6).
25. Using a suitable lifting device, position wheel (2, Figure 47) on
spindle assembly (6) and install bearing (3) cone on spindle.
NOTE: Prior to installing bearing (3) cone, pack cavity between

bearings with grease. Wipe excess grease from end of
spindle once bearing (3) cone is installed.
Figure 47
26. NON-ALL WHEEL DRIVE AXLE ONLY: Install retainer (8,

Figure 48) without shims.
27. Install two drilled head bolts (7, Figure 48) and torque to 60 Ibf ft
(8.3 kgam) (Lubricated) while rotating wheel to assure proper
seating of bearings.
28. Back out two drilled head bolts (7, Figure 48). Tap wheel hub with
hammer to ensure that bearing (3) cone moves outward slightly to
remove preload. Retorque bolts to 15 Ibf ft (2.1 kg*m) while rotating
wheel.
15352
Figure 48
26
29. NON-ALL WHEEL DRIVE AXLE ONLY: Using a depth micrometer

(9, Figure 49), measure distance “A” from retainer plate (8) outside
surface to end of spindle (6). Record this measurement in following
step.
Figure 49
30. NON-ALL WHEEL DRIVE AXLE ONLY: Remove two drilled head
bolts (7, Figure 50) and retainer plate (8).
31. Using a micrometer, measure thickness “B” of retainer plate (8).

Record this measurement.
32. Subtract measurement “B” from “A.” Subtract 0.003 In. (0.076 mm)
from the difference to obtain required shim pack (9) thickness. This
will apply a 0.003 In. (0.076 mm) preload to bearings.
Measurement “A”
Measurement “B”
Difference between “A” and “B”
0.003” Preload measusrement
Required shim pack thickness

L
Figure 50
27
33. NON-ALL WHEEL DRIVE AXLE ONLY: Position shims (9,

Figure 51) and retainer plate (8) on spindle.
I.
34. Install two drilled head bolts (7, Figure 51). Tighten bolts to 60 Ibf
ft (8.3 kgam) (Lubricated).
35. Once bolts are installed lockwire them into position.
E
L
36. NON-ALL WHEEL DRIVE AXLE ONLY: Install gasket and hub cap
(10, Figure 52) with four lock washers and bolts (11). Tighten bolts
to 24 Ibf ft (3.3 kgam).
Figure
1
51
37. ALL WHEEL DRIVE GEARBOX ONLY: Refer to appropriate Shop

Manual Section for the All Wheel Drive Gearbox reassembly.
I
L
Figure 52
28
INSTALLATION
1. Sling front axle assembly (1, Figure 53) with chains and
overhead hoist and lift into place under grader frame.
Figure 53
2. Install locating pin (not shown), and front and rear pivot
caps (2, Figure 54) with eight bolts and flat washers (1).
NOTE: Rear cap has hole for locating pin and front cap
does not. Make sure they are installed this way.
Align locating pin with hole in pivot pin and rear
pivot cap.
3. Tighten bolts as specified in “Front Axle Torque Values”

section of this manual.
15350A
Figure 54
4. Install hoses (1, Figure 55) to leaning wheel cylinder (2)

according to tags made as removal.
5. ALL WHEEL DRIVE AXLE ONLY: Refer to appropriate

Shop Manual Section for the All Wheel Drive Gearbox
Assembly. This manual will show additional hoses and
sensors that must be connected and installed as tagged
during removal.
Figure 55
29
6. Install hoses (1, Figure 56) to steering cylinders (2)

according to tags made at removal.
Figure 56
7. Install tire and rim assembly with four rim clamps (2,
Figure 57) and lug nuts (1). Tighten lug nuts as
specified in “Front Axle Torque Values” section of this
manual.
NOTE: Make sure that rim is properly centered. Refer

to Operator’s Manual for “Rim Centering. ”
Figure 57
8. With parking brake set, raise front tires clear of the

ground with moldboard of the machine.
9. Have another person remove blocking (1, Figure 58)

from under drawbar ball joint (2).
A WARNING! Use extreme care when

removing blocking from under frame.
Figure 58
30
10. Install tie rod assembly (1, Figure 59) with flat washer,
slotted nut (3) and cotter pin (2). Tighten slotted nut to
170 Ibf ft (23.5 kgam). If necessary, increase torque on
nut to install cotter pin.
NOTE: A f/at washer must be used under the slotted

nut. Install a f/at washer if one was not present
at disassembly.
Figure 59
11. Install grease zerk (1, Figure 60) into bottom of drawbar
ball joint socket (2).
Figure 60
NOTE: See “Front Wheel Alignment and Turning Radius Adjustment” section of this manual for adjustment of
steering cylinders.
NOTE: See appropriate Shop Manual Section for “All Wheel Drive Gearbox Assembly” (A WD only).
NOTE: See appropriate Shop Manual Section for “All Wheel Drive Motor” (A WD only).
31
G-09.30K
Rl
FINAL DRIVE ASSEMBLY
(JOHN DEERE TeamMate II)
WITH PLANETARY AND
NON-PLANETARY REDUCTION
(NoSPIN & LOCK/UNLOCK
DIFFERENTIALS)
GD530 SERIES 200417 & Up

GD530AW SERIES 200417 & Up
GD650A SERIES 200417 & Up
GD670A SERIES 200417 &. Up
CAUTION
ALL JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST BE IN GOOD
WORKING ORDER.

INJURY.
KOMATSU AMERICA INTERNATIONAL COMPANY 850 SOUTH STREET GALION, OH 44833
0196
Refer to “General Torque Values” shop manual section when SPECIFIC TORQUES are not given in this shop
manual section. All values listed throughout this manual are lubricated (WET) unless stated otherwise.
METRIC CONVERSIONS
TABLE OF CONTENTS
CONTENTS PAGE
LOCATIONONMACHINE ............................................... 4
DESCRIPTION ........................................................ 4
SERVICE DIAGNOSIS ................................................. 22
NoSPlN ........................................................ ..2 3
BRAKE DISC INSPECTION .......................................... 25
SERVICE/SPECIAL TOOLS ............................................. 26
SPREADER BAR AND CHAINS ...................................... 26
DIFFERENTIAL BACKLASH TOOL (DR08-111) ......................... 27
LUBRICANTS AND SEALANTS .......................................... 28
SPECIAL TORQUES ................................................... 28
TESTS AND ADJUSTMENTS ............................................ 28
PARKING BRAKE BLEEDING ........................................ 28
PARKING BRAKE ADJUSTMENT. .................................... 29
FINAL DRIVE BRAKE BLEEDING ..................................... 30
ROADTESTING ................................................... 31
SERVICING .......................................................... 32
REMOVAL ........................................................ 32
DISASSEMBLY GENERAL .......................................... 37
DISASSEMBLY OF PLANETARY CARRIER ............................ 37
DISASSEMBLY OF NON-PLANETARY CARRIER ....................... 43
DISASSEMBLY OF DIFFERENTIAL BRAKE PISTONS .................... 47
DISASSEMBLY OF INPUT QUILL ASSEMBLY .......................... 48
DISASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL ... 50
Disassembly of NoSPlN Differential Quills ........................... 50
Disassembly of Ring Gear and NoSPlN Differential ................... 50
Disassembly of Miscellaneous NoSPlN Differential Items ............... 51
DISASSEMBLY OF DIFFERENTIAL CASE WITH
LOCK/UNLOCK DIFFERENTIAL ............................... 52
Disassembly of Lock/Unlock Differential Quills ....................... 52
Disassembly of Ring Gear and Lock/Unlock Differential ................ 53
Disassembly of Differential Pinions ................................. 57
Disassembly of Miscellaneous Lock/Unlock Differential Items ........... 57
CLEANING AND INSPECTION ....................................... 58
REASSEMBLY GENERAL ........................................... 62
REASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL .... 63
Reassembly of NoSPlN Differential Miscellaneous Items ............... 63
Reassembly of Ring Gear and NoSPlN Differential .................... 63
Preload Adjustment of NoSPlN Differential Quills ..................... 64
REASSEMBLY OF DIFFERENTIAL CASE WITH
LOCK/UNLOCK DIFFERENTIAL ............................... 66
Reassembly of Lock/Unlock Differential Miscellaneous Items ........... 66
Reassembly of Ring Gear and Lock/Unlock Differential ................ 66
Preload Adjustment of Lock/Unlock Differential Quills .................. 71
PINION GEAR CONE POINT ADJUSTMENT ........................... 74
Rl
PINION GEAR ENDPLAY ADJUSTMENT .............................. 77

PINION GEAR INPUT QUILL INSTALLATION AND
BACKLASH ADJUSTMENT .................................. 77
RING GEAR AND PINION ROLLING PATTERN CHECK ................. 78
FINAL ASSEMBLY OF DIFFERENTIAL CASE .......................... 79
REASSEMBLY OF DIFFERENTIAL BRAKE PISTONS ................... 80
REASSEMBLY OF NON-PLANETARY CARRIER ....................... 81
REASSEMBLY OF PLANETARY CARRIER ............................ 89
INSTALLATION ................................................... 95
Rl 2
3 Rl
LOCATION ON MACHINE
The final drive assembly is located between tandem cases on machine.
DESCRIPTION
38
36\ \I----39
33
17324
Figure 1 EXPLODED VIEW OF FINAL DRIVE WITHOUT PLANETARY REDUCT
ION AND
PERROT PARKING BRAKE (FOR MICO PARKING BRAKE SEE PARTS MANUAL
)
Rl
LEGEND FOR FINAL DRIVE WITHOUT PLANETARY
The exploded view shown on the previous page and legend shown here are to help identify parts and their
orientation to each other while servicing final drive without planetary. Some components mentioned during service
procedure may only be shown in this illustration.
1. BOLT 24. RETAINER, BEARING

2. WASHER, FLAT 25. O-RING
3. DISK, BRAKE 26. BOLT
4. BOLT SHAFT ASSEMBLY, AXLE
5. WASHER, FLAT 27. .SLEEVE, OUTPUT SHAFT
6. BRACKET, PARKING BRAKE 28. .SHAl=T, AXLE
7. SPACER, BRAKE BRACKET 29. RING, SPACER - NON-PLANETARY
a. GASKET, LIQUID - 300 ML CARTRIDGE 30. GEAR, BRAKE PLATE
9. CASE, DIFFERENTIAL (SEE Figure 3) 31, RING, RETAINING
10 RING, RETAINING 32. RING, RETAINING
11 BEARING, SPHERICAL ROLLER 33. SPROCKET, OUTPUT SHAFT
12 SEAL, OIL 34. SPACER, OUTPUT SPROCKET
13. SLEEVE, TANDEM MOUNTING 35. DOWEL, LOCATING
14. SEAL, GREASE 36. CALIPER ASSEMBLY, PARKING BRAKE
BEARING ASSEMBLY 37. BOLT
15. .BEARING, CONE 38. NUT
16. .BEARING, CUP 39. PIN, SPLIT
17. HOUSING, FINAL DRIVE - R.H. 40. JAM NUT
HOUSING, FINAL DRIVE - L.H. 41. FLAT WASHER
ia. BOLT 42. BOLT
19. WASHER, FLAT 43. FLAT WASHER
20. FIl-RNG, LUBE 44. BOLT
BEARING ASSEMBLY 45. SPRING
21. .BEARING, CUP 46. SUPPORT BAR
22. .BEARING, CONE 47. SPACER
23. SHIM - 0.13 mm 48. FLAT WASHER AND HEX NUT
SHIM - 0.18 mm
SHIM - 0.50 mm
Rl
/
16
32
/
31 17323
6
LEGEND FOR FINAL DRIVE WITH PLANETARY
orientation to each other while servicing final drive with planetary. Some components mentioned during service
1. BOLT 24 RETAINER, BEARING

2. WASHER, FLAT 25 O-RING
3. DISK, BRAKE 26 BOLT
4. BOLT 27 SPACER, PLANETARY
5. WASHER, FLAT 28 SHAFT, AXLE TANDEM
6. BRACKET, PARKING BRAKE 29. PLANETARY & RING GEAR (SEE Figure 11)
7. SPACER, BRAKE BRACKET 30. RING, RETAINING
8. GASKET, LIQUID - 300 ML CARTRIDGE 31. SPROCKET, OUTPUT SHAFT
9. CASE, DIFFERENTIAL (SEE Figure 3) 32. SPACER, OUTPUT SPROCKET
10. RING, RETAINING 33. DOWEL, LOCATING
11. BEARING, SPHERICAL ROLLER 34. CALIPER ASSEMBLY, PARKING BRAKE
12. SEAL, OIL 35. BOLT
13. SLEEVE, TANDEM MOUNTING 36. NUT
14 SEAL, GREASE 37. PIN, SPLIT
BEARING ASSEMBLY 38. SPACER
15 .BEARING, CONE 39. FLAT WASHER AND HEX NUT
16 .BEARING, CUP 40. JAM NUT
17 HOUSING, FINAL DRIVE - R.H. 41. FLAT WASHER
HOUSING, FINAL DRIVE - L.H. 42. BOLT
18 BOLT 43. FLAT WASHER
19. WASHER, FLAT 44. BOLT
20. FITTING, LUBE 45. SPRING
BEARING ASSEMBLY 46. SUPPORT BAR
21. .BEARING, CUP
22. .BEARING, CONE
23. SHIM - 0.13 mm
SHIM - 0.18 mm
SHIM - 0.50 mm
Rl
3
I
.
F\L
I
\ \
21
1 !
\
Figure 3 EXPLODED VIEW OF DIFFERE

NTIAL CASE ASSEMBLY
Rl 8
LEGEND FOR DIFFERENTIAL CASE ASSEMBLY
orientation to each other while servicing differential case assembly. Some components mentioned during service
1. PLUG 17. SCREW, BLEED

2. O-RING 18. BUSHING, BLEEDER
3. BOLT 19. O-RING
4. WASHER, FLAT 20. CASE
5. PLUG 21. PLUG
6. O-RING 22. O-RING
7. INPUT QUILL ASSEMBLY (SEE Figure 4) 23. NUT, HEX
8. DIFFERENTIAL ASSEMBLY (SEE Figure 9) 24. WASHER, FLAT
9. PIN, DOWEL 25. BOLT
10. O-RING 26. DIFFERENTIAL BEARING QUILLS (SEE Figure 6)
11. PLUG 27. BRAKES (SEE Figure 5)
12. O-RING 28. PLUG
13. PLUG 29. O-RING
14. O-RING 30. REDUCER
15. PLUG 31. BREATHER
16. O-RING
Rl
2
\ \
8
\
\
‘13l2
14
5645.01
Figure 4 EXPLODED VIEW OF INPUT QUILL ASSEMBLY
Rl 10
LEGEND FOR INPUT QUILL ASSEMBLY
The exploded view shown on the previous page and legend shown here are to help identity parts and their
orientation to each other while servicing input quill assembly. Some components mentioned during service
BEARING ASSEMBLY 7. .BEARING, CUP

1. .BEARING, CONE 8. .BEARING, CONE
2. .BEARING, CUP KIT, YOKE & SEAL
3. SHIM - .003 In. (0.076 mm) 9. .YOKE
SHIM - .005 In. (0.127 mm) .KIT, SEAL
SHIM - .OlO In. (0.254 mm) 10. ..SEAL
4. COVER, DIFFERENTIAL CASE 11. ..v-SEAL
5. SHIM 12. O-RING
SHIM 13. WASHER, SPECIAL
SHIM WASHER, SPECIAL
SHIM WASHER, SPECIAL
6. WASHER 14. NUT, CASTLE
BEARING ASSEMBLY 15. PIN, COTTER
11 Rl
rlgure 3 tArLuutU VltW UF BRAKE5
LEGEND FOR BRAKES
The exploded view and legend shown here are to help identify parts and their orientation to each other while
servicing brakes. Some components mentioned during service procedure may only be shown in this illustration.
1. PLATE, BACKING 5. SEAL, INNER PISTON

2. DISC, FRICTION 6. PIN, PISTON DOWEL
3. PISTON 7. PIN, BACKING PLATE DOWEL
4. SEAL, OUTER PISTON
NOTE: The brake portion of the axle assembly has several versions of pistons, brake discs and backing plates.
Always refer to the appropriate parts manual for serial number ranges and parts break down.
Rl 12
Figure 6 EXPLODED VIEW OF DIFFERENTIAL BEARING QUILLS
LEGEND FOR DIFFERENTIAL BEARING QUILLS
The exploded view and legend shown here are to help identity parts and their orientation to each other while
servicing differential bearing quills. Some components mentioned during service procedure may only be shown
in this illustration.
1. QUILL 4. .BEARING, CONE

2. SHIM - .003 In. (0.076 mm) BEARING ASSEMBLY
SHIM - .005 In. (0.127 mm) 5. .BEARING, CONE
SHIM - .OlO In. (0.254 mm) 6. .BEARING, CUP
BEARING ASSEMBLY 7. QUILL
3. .BEARING, CUP
13 Rl
),20 23
3
" Lo---20
17322
Figure 7 EXPLODED VIEW OF LOCK/UNLOCK DIFFERENTIAL ASSEMBLY
14
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL ASSEMBLY
servicing lock/unlock differential assembly. Some components mentioned during service procedure may only be
shown in this illustration.
1. BOLT 17. GEAR, BEVEL

2. COVER 18. WASHER, THRUST
3. PIN, SPRING 19. WASHER, THRUST
4. WASHER 20. ROLLER, NEEDLE
5. SPRING 21. PINION
6. DISK 22. WASHER, THRUST
7. PLATE, CLUTCH SEPARATOR 23. RING, RETAINING
8. PLATE, CLUTCH BACKING 24. SHAFT, PINION
9. HOUSING ASSEMBLY 25. GEAR, BEVEL
10. .PISTON 26. HOUSING
11. SEAL 27. BALL
12. SEAL 28. BALL
13. BUSHING 29. BOLT
14. PACKING 30. GEAR SET, PINION & RING
15. BOLT 31. RING
16. WASHER
15 Rl
G07HH05
Figure 8 EXPLODED VIEW OF LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE DIFFERENTIAL
servicing lock/unlock differential case oil line. Some components mentioned during service procedure may only
be shown in this illustration.
1. ADAPTOR 4. ADAPTOR
2. O-RING 5. O-RING
3. OIL LINE
Rl 16
5645.05
Figure 9 EXPLODED VIEW OF NoSPlN DIFFERENTIAL ASSEMBLY
LEGEND FOR NoSPlN DIFFERENTIAL ASSEMBLY
servicing NoSPlN differential assembly. Some components mentioned during service procedure may only be
1. BOLT 5. NoSPlN (SEE Figure 10)

2. WASHER, FLAT 6. COVER
3. HOUSING 7. BOLT
4. SET, RING GEAR & PINION
17 Rl
I 4 6
G07HH031
Figure 10 EXPLODED VIEW OF NoSPlN DIFFERENTIAL
LEGEND FOR NoSPlN DIFFERENTIAL
The exploded view and legend shown here are to help identity parts and their
orientation to each other while
servicing NoSPlN differential. Some components mentioned during service procedur
e may only be shown in this
illustration.
1. GEAR, SIDE 4. CLUTCH ASSEMBLY

2. RETAINER, CAM SPRING 5. STOP
3. SPRING 6. SPIDER ASSEMBLY
Rl 18
Figure 11 EXPLODED VIEW OF PLANETARY ASSEMBLY

& RING GEAR
LEGEND FOR PLANETARY ASSEMBLY & RING GEAR
The exploded view and legend shown here are to help identify parts
and their orientation to each other while
servicing planetary assembly and ring gear. Some components mention
ed during service procedure may only be
1. SHAFT, INPUT
RING, RETAINING 9. SHAFT, PLANET
2.
GEAR, SUN 10. WASHER, THRUST
3. 11. PINION, PLANET
4. PLATE, LOCK
BOLT, SPECIAL 12. BEARING, ROLLER
5. 13. SPACER, BEARING
6. CARRIER, PLANET
RING, RETAINING 14. WASHER, RETAINING
7.
15. WASHER, THRUST
8. GEAR, RING
19 Rl
Figure 12 CROSS SECTION OF NON-PLANETARY REDUCTION FINAL DRIVE
RI 20
Figure 13 CROSS SECTION PLANETARY REDUCTION
21 Rl
SERVICE DIAGNOSIS
PROBLEM POSSIBLE CAUSE CORRECTION
Loss of Lubricant Wrong type or not enough Add or change lubricant as

lubricant. required.
NOTE: If sudden loss of lubricant
in differential is observed, Loose drain plug. Tighten or replace plug.
check the oil level in the
tandem cases to see if it
Cracked case. Repair or replace case.
has risen above normal
level. If so, axle shaft seal
has failed or been Oil seal failure. Replace seals.
damaged.
Damaged oil seals. Replace seals.
Wrong torque on bolts. Tighten or replace screws.
Excessive noise - Continuous Worn bearings. Replace bearings.
Damaged or worn parts. Replace parts as necessary.
Loss of lubricant. Replenish lubricant. Determine

cause of leak and repair as
necessary.
Damaged or worn final drive or Replace gears as necessary.

planetary pinion gear.
Excessive noise - under load. Bevel pinion shaft adjustment to See “Pinion Gear Cone Point
tight. Adjustment” and “Pinion Gear
Endplay Adjustment” in this
manual.
Excessive noise - under no load. Worn bearings. Replace bearings.
Bevel pinion shaft adjustment too See “Pinion Gear Cone Point
loose. Adjustment” and “Pinion Gear
manual.
Rl 22
PROBLEM POSSIBLE CAUSE CORRECTION
Excessive Heat - Under load. Bevel pinion shaft adjustment too See “Pinion Gear Cone Point
tight. Adjustment” and “Pinion Gear
manual.
Loss of lubricant. Replenish lubricant. Determine

cause of leak and repair.
Wrong type or not enough Add or change lubricant as

lubricant. necessary.
To much lubricant. Drain excess oil.
Hydraulic oil mixed in with axle Check brake piston seals. Replace inner and outer piston
lubricant. (Indicated by oil level seals.
rising above differential level plug
since last check.)
NOTE: Low brake pressure will Check O-ring located between Replace O-ring.
also indicate if seals are differential case and cover.
leaking.
Axle lubricant leaking from Improper bolt torque. Tighten bolts to specified torque
between final drive housing, value.
spacer and/or ring gear, and
differential case. Insufficient sealer between parts. Disassemble and reseal.
NoSPlN
Two methods can be used to determine if NoSPlN unit is operating properly.
Method One
One is the static method which is accomplished by raising all four drive wheels off the ground by blocking frame.
Next, apply parking brake so drive shaft will not turn.
Have an assistant on a drive wheel of the opposite tandem case. Start test by rotating drive wheels as far as
possible in forward direction. Then with one person firmly holding the right wheel forward against the stop, rotate
left wheel rearward. Listen for regular indexing or clicking sounds. See “Notes on Testing.”
NOTE: Be sure right wheel is held firmly against stop or left wheel will not disengage.
23 Rl
Next, rotate both wheels rearward until they stop. With one person holding the right wheel firmly against the stop
in the rearward direction, rotate left wheel forward. Again listening for indexing or clicking sounds. Finally, repeat
these tests, except this time hold left wheel against stops and rotate right wheel forward and rearward.
Notes on Testing
If operating properly, rotating wheel should cam out easily by hand and rotate freely in both directions until direction
of rotation is reversed or pressure on opposite wheel is relaxed.
With standard type NoSPIN, clicking or indexing noise is normal and quite prominent as driven clutch alternately
disengages from spider and then re-indexes with spider while it is rotating.
With silent-type NoSPlN used in articulated grader, however, only faint indexing noises will be heard, and possibly
none, until the direction of rotation is reversed. When reversed, the clutch will re-index and a slight noise should
be heard. If you do hear repeated loud indexing or clicking sounds when checking a silent-type NoSPIN, one of
the holdout ring and clutch assemblies may not be operating properly.
Method Two
The second method of testing a NoSPlN is by driving the machine. In checking to see that the NoSPlN is driving
both wheels, the driving test should be made under stress so some torque load is on the driving clutch teeth of the
NoSPIN. One way to get this load is to drive up against a solid obstruction in low gear in loose dirt or gravel and
see if you are able to spin both wheels in both directions.
NOTE: Stall the machine by putting excessive down pressure on the blade.
Another driving test is to check for proper camming action for both tandems in both directions. On a flat surface with
good traction conditions, drive the grader in a tight circle forward and rearward to the left and to the right to be sure
that the outside wheels are free and the outside tires do not scuff excessively. If the machine fails this test, find and
correct the problem.
Rl 24
SHOP MANUAL SECTION G-OQ.30K
BRAKE DISC INSPECTION
Brake discs can be checked on each side for wear through external inspection holes.
NOTE: These inspection ho/es also serve as oil level check holes.
NOTE: The one inspection ho/e may contain a 90 o elbow for maintaining proper oil level. Remove this elbow to
perform inspection.
INSPECTION
INSTRUCTIONS
L.H. INSPECTION HOLE

(REMOVE OIL LEVEL
SEE VIEW A
R.H. INSPECTION
PLUG _
NOTE: NOTCHES MUST BE
VISIBLE IN BRAKE
LINING ON BOTH
SIDES OF EACH
DISC.
VIEW A
VIEW INSIDE INSPECTION
PLUG HOLE
16487C
Figure 14 INTERNAL WET BRAKE INSPECTION POINTS
Every 3 Months or 500 Hours, the brake linings (1, Figure 14) must be inspected. This is accomplished by removing
the oil level elbow and inspection plug(s) from the inspection holes. Use a flash light, and check condition of brake
lining material. If brake facing material is worn to a point where oil grooves are no longer visible, or if other brake
wear is noted or braking problems have occurred, replace brakes.
25 Rl
SERVICE/SPECIAL TOOLS
SPREADER BAR AND CHAINS
Shown here are manufacturing details for the spreader used to hold chains apart while removing and installing axle
assembly.
(4) 0.125” HOLES rvrr \
1.500” (REF.1
(TY P.1
(TY P.1
x 1 Ii’2 x 3/16” ANGLE
I 15853
Figure 15 MANUFACTURING DETAILS FOR SPREADER BAR
Figure 16, shows how the spreader bar should be attached

between chains.
Two chains 17 Ft. (5.18 m) long with 0.375 In. (9.525 mm)
links are required.
NOTE: Spreader bar should be notched to receive 0.375 In.

(9.525 mm) chain link. Both ends of spreader must
be moused (locked) to chain, 6 Ft. (1.83 m) from
lifting eye(s). Chains must have a lifting capacity of
not less than 2 Tons (1.81 Mg).
A piece of wire passed through the two drilled holes and

twisted will hold chain in position in spreader bar.
16 SPREADER BAR AND CHAIN AR-

Figure
RANGEMENT
Rl 26
DIFFERENTIAL BACKLASH TOOL (DR08-111)
Shown here is the differential backlash tool DR08-111. The tool is designed to expand into the splines of the No-
Spin differential and have a bar rotate around its centerline at the same distance of the ring gear O.D. This tool must
be used. There is no physical way to measure the backlash once the pinion gear is installed.
I G07HH042 1
Figure 17
Figure 18, shows how the backlash tool is installed into the
No-Spin to measure the backlash of the ring gear. A dial
indicator set at the same O.D. of the ring gear is used to
measure the backlash on the bar.
GO7t&fQ&,
Figure 18
27 Rl
LUBRICANTS AND SEALANTS
The following is a comprehensive listing of lubricants and sealants used during overhaul of this component.
Loctite #505 or #I515

Loctite #12017
Locti te #242
Loctite #518 Master Gasket
Loctite #592
3M 2158 Epoxy
For lubricants refer to “Operation and Maintenance Manual” for latest specifications.
SPECIAL TORQUES
The following is a comprehensive listing of special torques used during overhaul of this component.
NoSPlN Differential Cover to Housing .......................................... 85 Ibf ft (11.8 kgem)

Ring Gear Mounting Bolts ................................................... 220 Ibf ft (30.4 kgem)
Differential Bearing Quills ..................................................... 66 Ibf ft (9.1 kgem)
Ring Gear Rolling Toque ............................................. 2.1 - 7.8 Ibf ft (0.3 - 1.1 kgem)
Parking Brake Mounting Bracket ........................................ 45 - 50 Ibf ft (6.2 - 6.9 kg-m)
Pinion Gear Castle Nut ........................................... 225 - 300 Ibf ft (31 .l - 41.5 kgem)
PinionGearRoilingTorque .............................................. 2-4Ibfft(0.3-0.6kgem)
Differential (Input Quill) Cover to Differential Case ................................ 229 Ibf ft (31.7 kgem)
Tandem Sleeve Retainer to Tandem Sleeve ............ Sixteen bolts per side 40 - 45 Ibf ft (5.5 - 6.2 kgem)
Eighteen bolts per side 50 Ibf ft (6.9 kgem)
Planetary Carrier to Axle .......................................... 600 - 650 Ibf ft (83.0 - 89.9 kgem)
Final Drive to Frame ........................................................ 580 Ibf ft (80.2 kg-m)
DriveShafttolnputYoke .............................................. 45-50Ibfft(6.2-6.9kg.m)
Tandem Case to Final Drive ................................................. 150 Ibf ft (20.7 kg-m)
Wheel Lug Nuts ........................................................... 115 Ibf ft (15.9 kg-m)
ParkingBrakeDisktolnputYoke ....................................... 45-50Ibfft(6.2-6.9kgom)
TESTS AND ADJUSTMENTS
PARKING BRAKE BLEEDING
1. Place blocking in front of and behind each tire to prevent accidental movement of grader.
2. Attach a clear plastic tube to parking brake caliper bleeder screw. Place other end of tube into a container with
clean hydraulic oil.
3. Close bleeder screw.
4. Start engine, and allow unit to run to ensure that hydraulic accumulators are filled with hydraulic oil. With
accumulators filled, “RELEASE” and “APPLY” parking brake switch several times.
5. Shutdown engine and “APPLY” parking brake.
6. With engine shutdown, open caliper bleeder screw. Turn ignition key “ONnBUT DO NOT START ENGINF.
Rl 28
7. Move parking brake switch to “RELEASED” position. This will cause hydraulic oil in the accumulator to purge
air from parking brake system.
8. Close bleeder screw.
9. Repeat Steps 4 thru 8, as many times as necessary so no air bubbles appear in plastic tube or container
holding oil.
PARKING BRAKE ADJUSTMENT
A WARNING! For safe operation, it is imperative that the parking brake always be kept correctly
adjusted and in proper working order.
The parking brake assembly is mounted to the rear axle assembly. The parking brake is a spring applied
hydraulically released mechanism. Under normal conditions, no periodic service adjustment is required. When
brake is released, a 0.015 In. (0.381 mm) to 0.125 In. (3.175 mm) gap is acceptable.
However if brake should need adjustment, use the following procedure:
1. Perrot parking brake caliper (Figure 19).
A. Park grader on a level surface. Rest moldboard and

all accessories solidly on ground.
B. Place blocking in front of and behind each tire.
C. Switch parking brake switch to “RELEASED”

position.
NOTE: Parking brake caliper is spring applied and

hydraulically released.
D. With one person in cab, have another person

remove rubber boot (1, Figure 19) from parking
brake caliper (2).
F:igure 19 MANUAL RELEASE OF BRAKE
E. With caliper still pressurized, loosen jam nut (3, CALIPER
Figure 19) and turn adjustment screw (4) clockwise
(“IN”) until both brake pads (5 and 6) are in solid contact with brake disc (7).
F. With both brake pads (5 and 6, Figure 19) in contact with disc (7), turn adjustment screw (4) “OUT” until
0.030 In. (0.762 mm) clearance is obtained. Then tighten jam nut (3) to hold it in position.
G. install rubber boot (1, Figure 19) on caliper (2).
2. Mica parking brake caliper (Figure 20).
A. Park grader on a level surface. Rest blade and all accessories solidly on ground.
B. Place blocking in front of and behind each tire.
29 Rl
C. Switch parking brake switch to “RELEASED” position.
NOTE: Parking brake caliper is spring applied and hydraulically released.
D. With one person in cab, have another person,

loosen hex nut (1, Figure 20) and turn adjustment
set screw (2) clockwise (“lNn) until both brake pads
(3 and 4) are in solid contact with brake disc.
E. With both brake pads (3 and 4, Figure 20) in

contact with disc, turn adjustment set screw (2)
“OUT” until 0.012 In. (0.305 mm) clearance is
obtained. Then tighten hex nut (1) to hold it in
position.
16996
Figure 20
FINAL DRIVE BRAKE BLEEDING
1. Place blocking in front of and behind each tire to prevent accidental movement of grader.
2. Attach a clear plastic tube to each final drive wet brake bleeder screw. Place other end of tube into a container
with clean hydraulic oil.
NOTE: Bleeder screws are located on top of final drive.
3. Close bleeder screws.
4. Start engine, and allow unit to run to ensure that hydraulic accumulators are filled with hydraulic oil. With
accumulators filled, “RELEASE” and “APPLY” foot brake several times.
5. Shutdown engine.
6. With engine shutdown, open final drive bleeder screws.
7. Apply foot brake. This will cause hydraulic oil in the accumulators to purge air from final drive brake system.
8. With foot brake still applied, close bleeder screw.
9. Repeat Steps 4 thru 8, as many times as necessary so no air bubbles appear in plastic tubes or container
holding oil.
Rl 30
ROAD TESTING
After tandems and final drive are reinstalled, and brake lines bled, the grader must be road tested. This will ensure
that tandems, final drive and brakes are functioning properly, before returning unit to service.
1. Start engine and pump brakes for several minutes with the transmission in “NEUTRAL.” Look for signs of
hydraulic oil leaks. Correct any leaks if found.
2. The brake pedal should have a solid feel. If spongy, bleed brake system again.
3. Test brakes at low travel speed. Increase speed slowly in one (1) to two (2) MPH increments coming to a
complete stop between each speed increase. Test brakes in forward and reverse directions.
4. Test parking brake as outlined in “Parking Brake Adjustment” section of this manual.
5. Again look for signs of oil leaks, and correct if necessary.
6. Recheck all oil levels.
31 Rl
SERVICING
Thefollowing is only one method of obtaining a removal, disassembly, cleaning and inspection, reassembly, and
installation of the final drive assembly.
Thoroughly clean component to be serviced and surrounding area. This will help prevent contamination from
entering component or system being serviced.
REMOVAL
1. Park grader where both tandems and all four rear tires are within reach of a 2 Ton lifting device. Position
moldboard crossways under grader resting solidly on ground. Shutdown engine.
2. Remove transmission guard (1, Figure 21) from frame (if

equipped). Position a floor jack under guard. Remove
two hex nuts (4), flat washers (3), and bolts (2) on each
side, and four hex nuts, flat washers and bolts (5) on
rear.
A WARNING! Be sure that transmission

guard is adequately supported.
Figure 21
3. Remove parking brake caliper.

r) 1
A. Start engine and release parking brake.
B. With operator in cab have another person turn

parking brake release valve (1, Figure 22) fully CW
to close it. This will hydraulically lock the parking
brake caliper in the “RELEASED” position.
C. Shutdown engine.
Figure 22
Rl 32
D. Perrot parking brake caliper removal. I
1) Loosen and remove jam nut (1, Figure 23)

spring (2), washer (3) and bolt (4) from caliper
(5) and support bar (6).
2) Remove two nuts and washers (7, Figure 23),

spacers (8) washers (9) and bolts (10) that hold
support bar (6) to parking brake bracket (1 l),
3) Remove cotter pin (12, Figure 23), nut (13) and

bolt (14) from each end of parking brake caliper
(5) and parking brake bracket (11).
A WARNING! Do not place fingers

between caliper brake pads.
4) Tie caliper (5, Figure 23) up out of way of final

drive.
NOTE: If caliper can not be hydraulically released, tag and disconnect hose from caliper. Leave
caliper on mounting bracket until it is removed from under unit (as shown in Figure 33). It will
be easier to remove caliper when it is out from under unit. Refer to “Operation and
Maintenance Manual” for a manual release procedure.
E. Mica parking brake caliper removal.
1) Remove four hex nuts, eight flat washers and

four bolts (1, Figure 24) securing caliper mount
assembly (2) to parking brake bracket (3).
A
WARNING! Do not place fingers
2) With caliper mount assembly (2, Figure 24)

and caliper (4) removed from parking brake
bracket (3), tie them up out of the way of final
drive.
NOTE: If caliper can not be hydraulically Figure 24

released, tag and disconnect hose
from caliper. Leave caliper on mounting bracket until it is removed from under unit (as shown
in Figure 33). It will be easier to remove caliper when it is out from under unit. Refer to
“Operation and Maintenance Manual” for a manual release procedure.
33 Rl
4. Tag and disconnect brake hose (1, Figure 25) from fitting
(2) on each side of final drive (3). Plug hoses to prevent
contamination from entering hydraulic system.
A
WARNING! ACCUMULATOR in brake
system. Do not depress foot brake when
brake hose is disconnected. Hoses must
be capped to prevent accidental
discharge of hydraulic fluid from
accumulator.
5. Remove fittings (2, Figure 25) from final drive (3).

Replace O-ring (4) on each fitting, if necessary. Plug
brake ports to prevent contamination from entering brake
portion of final drive. Figure 25
NOTE: If unit is equipped with a lock/unlock differential,

tag and disconnect the supply and return lines. Plug and cap hoses and fittings.
6. Disconnect (-) negative battery cables from batteries to prevent accidental starting of unit.
7. Drain tandem cases and final drive. Refer to “Operation and Maintenance Manual” for capacities.
8. Place a 10 Ton jack (1, Figure 26) under rear of each

tandem case (2). Place adequate blocking or support
stand (3) under rear of frame (4) to support unit when
jacks are removed. Remove jacks.
NOTE: With heel of moldboard positioned in front of

rear tires, extending one lift cylinder at a time
will also raise rear of frame, to place blocking
under it. DO NOT support grader with
moldboard.
Figure 26
9. Using a suitable lifting device and tire tongs, remove

eight lug nuts and wheel clamps (1, Figure 27), and tire
from wheel.
10. Repeat procedure for remaining tandem tires.
Figure 27
Rl 34
11. Place jack(s) and blocking (1, Figure 28) under tandem
case (2). If not previously done, remove drain plug (3)
from side of case and drain and discard old oil. Reinstall
drain plug.
NOTE: On some tandems the drain plug is located at

position (6, Figure 28) on either one end or the
other.
NOTE: Tandem case holds approximately 8.7 U.S.

Gallons (32.9 J).
12. Remove four side access hole covers (4, Figure 28) and
two top access covers (5) from tandem case. 16377A
Figure 28
13. Rotate final drive input shaft until master link (1, Figure
29) is accessible through side access hole.
NOTE: Parking brake caliper must be released to rotate

shaft. See Steps 3.8 and 3.A.
NOTE: If input shaft will not move chain, turn wheel until
master link is in position.
14. Remove master link from chain (2, Figure 29).
NOTE: There are two different types of chains used in

the tandem case. A double strand chain is used
with a non-planetary axle. Single strand chain is 16371
used with a planetary reduction axle. The Ygure 29

master links and components for these chains
are shown in Figure 30 and Figure 31.
Figure 30 DOUBLE STRAND CHAIN MASTER Figure 31 SINGLE STRAND CHAIN MASTER
LINK (NON-PLANETARY AXLE) LINK (PLANETARY REDUCTION AXLE)
35 Rl
15. Position two jacks under tandem case (1, Figure 32) so
it will remain level.
16. Using a 2 ton (1,814 kg) lifting device, sling tandem case
(1, Figure 32) as shown.
17. Remove twenty-four bolts and washers that secure

tandem case (1, Figure 32) to final drive.
NOTE: The seven bolts at top of final drive can not be

removed until tandem case is separated from
final drive.
18. Repeat preceding steps for remaining tandem case.

Figure 32
19. If not previously done, remove drain plug from final drive
assembly (1, Figure 33) and discard old oil. Reinstall
drain plug.
NOTE: Refer to “‘Operation and Maintenance Manual”

for oil capacity of final drive assembly.
20. Using a suitable lifting device and spreader, sling final

drive assembly (1, Figure 33) as shown. Position a jack
under brake disc (2) to prevent tipping of final drive as it
is lowered away from frame (3).
NOTE: See ‘Special Tools” for manufacturing details of

spreader bar and chains.
Figure 33
21. Disconnect drive shaft (4, Figure 33) from input yoke (5).
22. Remove eight bolts and washers (6, Figure 33) that secure final drive to frame. Lower final drive to ground and
slide it out from under unit.
Rl 36
DISASSEMBLY GENERAL
1. Once final drive assembly is removed from grader it must be disassembled according to whether it has
planetary or non-planetary reduction, and a NoSPlN or a lock/unlock differential.
DISASSEMBLY OF PLANETARY CARRIER
1. Using a suitable lifting device, position and secure

differential case (1, Figure 34) with final drive (2) on an
adequate table or stand.
2. Using a suitable lifting device, sling final drive assembly

(2, Figure 34). Remove bolts and flat washers and final
drive from differential case (1).
3. Remove locating dowels (3, Figure 34) from differential

case (1).
Figure 34
4. Remove friction disc (3, Figure 35) from backing plate (1)
and sun gear (4).
5. Remove backing plate (1, Figure 35) from dowels (2).
NOTE: A factory rollover stand (shown in background)

was used during this service procedure.
Figure 35
37 Rl
6. Remove three brake backing dowels (4, Figure 36) from

ring gear (5).
7. Remove sun gear (1, Figure 36) with input shaft (2) from
carrier (3).
Figure 36
8. Slide input shaft (3, Figure 37) out of sun gear (2).
9. Remove retaining ring (1, Figure 37) from sun gear (2),
Figure 37
10. Remove triangular lock plate (1, Figure 38) from carrier
(2) and bolt (3).
Figure 38
Rl 38
11. Install a piece of bar stock (1, Figure 39) as shown, to

hold planet carrier (2) and ring gear (3) in position. Then
turn assembly over.
Figure 39
12. Remove retaining ring (3, Figure 40) and output shaft
sprocket (1) from axle (2).
Figure 40
13. Remove output sprocket spacer (4, Figure 41) from axle
(5).
14. Remove retaining ring (3, Figure 41) that secures

spherical roller bearing (1) in tandem mounting sleeve
(2).
Figure 41
39 Rl
15. Remove bolt (1, Figure 42), retaining washer (2) and
brass thrust washer (not shown) from carrier (3) and axle
shaft.
Figure 42
16. Using a suitable lifting device, install an eye bolt (1,

Figure 43) into axle shaft. Lift axle shaft and carrier
assembly (2) from final drive assembly (3).
17. Remove ring gear (4, Figure 43) and locating dowels
(not shown) from final drive assembly (3).
i a.Remove spherical roller bearing (1, Figure 41) from

tandem mounting sleeve (2, Figure 41)
Figure 43
19. Remove carrier assembly (2, Figure 44) and planetary

spacer (1) from axle shaft (3).
I G07HH021
Figure 44
Rl 40
20. Pry retaining ring (1, Figure 45) out of groove in end of
pinion shaft (7). Press shaft out of carrier (2) and
planetary gear (5).
21. Slide thrust washers (6, Figure 45) and planetary gear
(5) out of carrier (2).
22. Remove forty eight bearing rollers (4, Figure 45) and
bearing spacer (3) from planetary gear (5).
23. Repeat Steps 20 thru 22, for remaining two planetary

gears.
Figure 45
24. Remove bolts (1, Figure 46), retainer plate (2) and shims
(not shown) from tandem mounting sleeve (3).
Figure 46
25. Remove bearing cone (3, Figure 47) from tandem

mounting sleeve (1).
26. Using a suitable lifting device, sling final drive housing (2,
Figure 47). Remove housing from tandem mounting
sleeve (1).
Figure 47
41 Rl
27. Remove oil seal (1, Figure 48) from tandem mounting
sleeve (2).
I co7HHoo:
Figure 48
28. Remove bearing cup (5, Figure 49) from inboard end of
final drive housing (4).
29. Remove grease seal (3, Figure 49), bearing cone (2)
and bearing cup (1) from outboard end of final drive
housing (4).
30. Remove grease fitting (6, Figure 49) from final drive
housing (4), if replacement is necessary.
Figure 49
Rl 42
DISASSEMBLY OF NON-PLANETARY CARRIER
1. Using a suitable lifting device, position and secure

differential case (1, Figure 50) with final drive (2) on an
adequate table or stand.
2. Using a suitable lifting device, sling final drive assembly

(2, Figure 50). Remove bolts and flat washers and final
drive from differential case (1).
3. Remove locating dowels (3, Figure 50) from differential

case (1).
Figure 50
4. Remove friction disc and brake plate gear assembly (3,

Figure 51) from backing plate (1) and axle shaft (4).
5. Remove backing plate (1, Figure 51) from dowels (2).
NOTE: A factory rollover stand (shown in background)

was used during this service procedure.
Figure 51
6. Remove retaining ring (1, Figure 52) and friction disc (3)
from brake plate gear (2). Remove remaining retaining
ring (4) from gear if replacement is necessary.
I GO7HHOl~
Figure 52
43 Rl
7. Remove three brake backing plate dowels (1 thru 3,

Figure 53) and spacer (4) from final drive housing (5).
NO TE: On later built axles the spacer (4) is cast as an

integral part of the housing (5). The one piece
spacer/housing and the separate spacer and
housing are available from the parts
department. In the event that a one piece
spacer/housing in not available a separate
housing and spacer may be substituted, along
with an additional two locating dowels.
Figure 53
8. Remove locating dowels (1, Figure 54) from final drive

housing (2).
Ygure 54
9. Remove retaining ring (3, Figure 55) and axle assembly

(1) from tandem mounting sleeve (2).
Figure 55
Rl 44
10. Remove retaining ring (7, Figure 56), sprockets (4 and

5), output sprocket spacer (3), spherical roller bearing
(2), and output shaft sleeve (1) from axle shaft (6).
I GO7HiOH
Figure 56
11 Remove bolts (1, Figure 57) retainer plate (2) and shims
(not shown) that hold tandem mounting sleeve in final
drive housing (3).
Figure 57
12. Remove bearing cone (3, Figure 58) from tandem

13. Using a suitable lifting device, sling final drive housing (2,
Figure 58). Remove housing from tandem mounting
sleeve (1).
Figure 56
45 Rl
14. Remove oil seal (1, Figure 59) from tandem mounting
sleeve (2).
I
Figure 59
15. Remove bearing cup (5, Figure 60) from inboard end of
final drive housing (4).
16. Remove grease seal (3, Figure 60), “GCIIII ‘3 ““I I” \-,
and bearing cup (1) from outboard end of final drive
housing (4).
17. Remove grease fitting (6, Figure 60) from final drive
housing (4), if replacement is necessary.
0’
6
Figure 60
Rl 46
GO4AVOOl
Figure 61
1. Remove piston (1, Figure 61) and three dowels (2) from each side of differential case (3).
2. Remove inner seal (4, Figure 61) and outer seal (5) from each side of differential case (3).
47
DISASSEMBLY OF INPUT QUILL ASSEMBLY
n and Maintenance Manual”

1. If parking brake caliper (1, Figure 62) has not been removed, refer to “Operatio
(4) from parking brake bracket
for “Manual Release” method. Remove spacers (2), support bar (3) and spring
(5).
3. E for mica parking brake
NOTE: See “Removal”section, Step 3.D for perrot parking brake caliper, or Step
caliper, for additional information.
Rl 48
2. Remove fourteen bolts (3, Figure 3) and flat washers (4,

Figure 3) that secure differential case cover (14, Figure
62) to differential case.
NOTE: Threaded jacking ho/es (‘A,” Figure 63) are

provided on each side of the cover to help break
it free from the case.
3. There are two jacking holes in differential case cover

(14, Figure 62). One hole is located on each side of
cover, on horizontal centerline, of input yoke. Remove
cover and two O-rings (10, Figure 3) from case.
4. Remove eight bolts and flat washers (11, Figure 62) and
brake disk (12) from yoke (13), if replacement of disk is
necessary.
5. Remove cotter pin (6, Figure 62), castle nut (7), special
washer (6) and O-ring (9) from pinion gear (10).
6. Remove yoke (13, Figure 62) from pinion gear (10). 16797A
Figure 63
7. Remove V-seal (15, Figure 62) from yoke (13).
a. Using and arbor press and suitable adaptor, press pinion gear (10, Figure 62) out of bearing cone (17).
9. Remove washer (19, Figure 62) and pinion endplay shims (20) from pinion gear (10).
NOTE: Set pinion endplay shims (20) aside so they can be used as a starting point for pinion endplay shim
pack thickness at reassembly.
10. Remove seal (16), bearing cone (17), and bearing cup (1 a), from differential case cover (14).
11. Remove cone point shims (21, Figure 62) and bearing cup (22) from differential case cover (14).
12. Remove bearing cone (23, Figure 62) from pinion gear (lo), if replacement of either part is necessary.
NOTE: If pinion gear or ring gear is replaced, the other one must replaced. They are a matched set.
13. Remove eight bolts and flat washers (24, Figure 62), parking brake bracket (5) P/N 1263 956 Hl , and brake
bracket spacer (25) from differential case cover (14).
NOTE: On differentials with mounting bracket P/N 1430 033 HI, the bracket is held on with only five bolts and
f/at washers. Also, spacer (25) has been eliminated.
49 Rl
DISASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL
Disassembly of NoSPlN Differential Quills
1. Mark position of ring gear on differential case for

reassembly. It is possible to install ring gear and
differential assembly (1, Figure 64) in case backwards.
2. Using a suitable lifting device, sling ring gear and

differential assembly (1, Figure 64).
3. Remove bolts and flat washers (2, Figure 64), bearing

quills (3 and 4) and shims (5 and 6) from case.
NOTE: There is one nut and f/at washer (7, Figure 64)
on inside of case for each quill. It is located at
bolt hole closest to case opening.
4. Remove bearing cups (8 and 9, Figure 64) from quills (3

and 4) if replacement either part is necessary.
Figure 64
Disassembly of Ring Gear and NoSPlN Differential
1. Insert a 5/l 6” Dia. threaded rod 18” Long (1, Figure 65)
through differential assembly. Install a 3.000 In.
(76.200 mm) O.D. washer on each end of threaded rod
with appropriate hex nuts (2). Tighten hex nuts and
washers against housing (3) and cover (4). This rod will
retain spring pressure exerted by NoSPlN springs.
2. Match mark housing (4, Figure 65), differential spider (5),

and cover (3) as shown with a diagonal match mark.
This style of match mark will ensure that differential is
properly reassembled.
3. Remove bolts (6, Figure 65) holding housing and cover

together.
Figure 65
4. Once bolts are removed, slowly unscrew hex nuts on
threaded rod to allow housing and cover to separate.
This will allow NoSPlN springs to expand.
Rl 50
5. Remove threaded rod and NoSPlN parts (1 thru 6, Figure 10) in order shown from between housing and
cover.
6. Using a suitable puller remove bearing cones (7 and 8, Figure 65) from housing (4) and cover (3).
7. Remove ring gear bolts and flat washers (9, Figure 65) and ring gear (10) from housing.
NOTE: Bolts are secured in position with 3M 2 158 Epoxy.
NOTE: If ring gear or pinion gear is replaced, the other one must be replaced. They are a matched set.
Disassembly of Miscellaneous NoSPlN Differential Items
1. Remove alignment dowels (9, Figure 3) from differential case (20), if replacement is necessary.
2. Remove plugs (1,6,11,13,15,21, and 28, Figure 3) from differential case (20) and cover (7). Remove O-rings
from plugs if replacement is necessary.
3. Remove breather (31, Figure 3) and reducer (30) from differential case (20).
4. Remove bleeder screw (17, Figure 3), bleeder bushing (18) and O-ring (19) from differential case (20)
51 Rl
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL
Disassembly of Lock/Unlock Differential Quills
1.
Figure 66
2. Mark position of ring gear on differential case for

reassembly. It is possible to install ring gear and
differential assembly (1, Figure 67) in case backwards.

4. Remove bolts and flat washers (2, Figure 67), bearing

quills (3 and 4) and shims (5 and 6) from case.
NOTE: There is one nut and f/at washer (7, Figure 67)
on inside of case for each quill. It is located at
bolt hole closest to case opening.
5. Remove bearing cups (8 and 9, Figure 67) from quills (3

and 4) if replacement either part is necessary.
Figure 67
Rl 52
Disassembly of Ring Gear and Lock/Unlock Differential
1. Match mark one end of each pinion shaft to the

lock/unlock differential housing halves. this will ensure
that shafts are installed in same location at reassembly.
Use one straight and one 45” angled line as shown in
Figure 68.
2. Remove eight bolts (1, Figure 68) that hold lock/unlock

differential housing halves (2 and 3) together.
Figure 66
3.
Figure 69
4. Remove bevel gear (1, Figure 70) from pinion set (2)
5. Remove pinion set (2, Figure 70) as a unit and carefully

set aside.
Figure 70
53 Rl
6. Remove inside bevel gear (1, Figure 71) and thrust

washer (2) from ring gear side of differential housing (3).
Figure 71
7. Remove pinion thrust washer (1, Figure 72), bearing

thrust washer (2), pinion gear (3), twenty-six roller
bearings (4), bearing thrust washer (5) and retaining
ring (6) from each end of both pinion shafts (7).
NOTE: Keep al/parts together so they can be installed

on the same pinion shaft end they were
removed from.
Figure 72
8. Remove bolts (1, Figure 73) and cover (2) from ring gear
half of differential assembly (3).
9. Using a suitable puller remove bearing cone (4) from

cover (2), if replacement is necessary.
10. Remove ring gear bolts and flat washers (5, Figure 73)
and ring gear (6) from housing.
NOTE: Bolts are secured in position with 3M 2158

Epoxy. 168OC
NOTE: If ring gear or pinion gear is replaced, the other Figure 73

one must be replaced. They are a matched set.
Rl 54
11. Remove four disk plates, three clutch separator plates

and clutch backing plate (1, Figure 74) from housing (2).
12. Remove three return springs (3, Figure 74) from housing
(2).
I 16811
Figure 74
13. Remove three pins (1, Figure 75) from cover (2), if
replacement is necessary.
14. Test springs (3, Figure 75) for proper free length and
compressed force. Replace springs as a set if one or
more of them do not meet the following specifications.
Free Length 1.6 In. (40.64 mm) (approximate)

Test Length 1 .l In. (27.94 mm) at 23 - 28 lb force
(102 - 125 N)
Figure 75
15. Using a rubber-tipped nozzle air hose, remove

differential lock piston (1, Figure 76) from housing (2).
Figure 76
55 Rl
16. Remove seals (1 and 2, Figure 77) from piston bore.
Figure 77
17. Using a suitable puller, remove bearing cone (1, Figure

78) from housing (2).
Figure 78
Rl 56
Figure 80
Figure 79
18. Unlock and remove two sealing rings (1, Figure 79) from housing (2). Open the rings slightly to remove.
Disassembly of Differential Pinions
Disassembly of Miscellaneous Lock/Unlock Differential Items
1. Remove alignment dowels (9, Figure 3) from differential case (20), if replacement is necessary.
2. Remove plugs (1,6,11,13,15,21, and 28, Figure 3) from differential case (20) and cover (7). Remove O-rings
from plugs if replacement is necessary.
3. Remove breather (31, Figure 3) and reducer (30) from differential case (20).
4. Remove bleeder screw (17, Figure 3), bleeder bushing (18) and O-ring (19) from differential case (20)
57 Rl
CLEANING AND INSPECTION
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign
material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as
thrust bearing, matched parts, etc.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved
and parts are thoroughly clean.
A WARNING! Care should be exercised to avoid inhalation of vapors, exposure to skin and
creating fire hazards when using solvent type cleaners.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then remove
bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly
clean. To dry bearings, use moisture-free compressed air. Be careful to direct air stream across bearing to
avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING; bearings may be
rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing mating cup or cone at the same time. After
inspection, dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them until
installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective bearing
housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of
any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal
casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals.
If this happens, that portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
Rl 58
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye. Examine
teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks
or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that are deeply
grooved or scratched which would affect their operation.
NoSPIN: DIFFERENTIAL
1. Inspect splines on side gears and clutches. Remove any burrs or small chipped edges with an abrasive stone
or electric burr grinder. If any sections of spline are broken away, replace NoSPIN. Check side gear hubs for
fractures.
2. Carefully, examine differential subcase. If trunnion holes are worn or scored, or if thrust surfaces on inside ends
of differential subcase are worn or scored, case should be replaced. Examine threads of all bolts, nuts and/or
bolts, and replace those which show indications of being stripped or damaged. It is a good practice also to
carefully examine bearings and ring gear for wear or damage.
3. Check thrust and bearing surfaces of subcase for signs of pick up of metal or wear. Replace if necessary.
4. Check each clutch and holdout ring assembly for correct indexing of holdout ring to cam ring. Be sure holdout
ring rotates on clutch with only a little resistance.
5. Check holdout rings in NoSPlN for fractures and chipping or excessive wear of teeth. If wear is evident, replace
assembly.
6. Check center cam for free movement. It must be free to rotate within limits of key in spider. It is not necessary
to remove center cam from spider, since these parts are serviced only as an assembly. If either part is
excessively worn or damaged, the complete spider-center cam assembly should be replaced.
7. Inspect clutch teeth on the spider and driven clutches. Very slight chips can be touched up with an abrasive
stone. If excessively chipped or rounded, the NoSPlN must be replaced. Check the tooth protruding radially
inward from the spider for signs of improper alignment with the gap in either holdout ring.
0. Assemblies must not be excessively chipped. A smooth wear pattern up to 50% of the cam face width is
acceptable.
9. Check the side gear spline fit on its mating axle shaft. Be sure splines do not bind. Also check internal side gear
splines for wear or chipping.
10. Check spring load with valve spring tester at 0.900” (22.86 mm) operating height. If reading is less than 115 Ibf
in (1.3 kgem) ilO%, replace NoSPIN.
59 Rl
LOCK/UNLOCK DIFFERENTIAL
1. inspect disks (1, Figure 81). Replace if:
A. Peening is evident or splines have backlash

B. Warping or coning exceeds 0.25 mm (0.010 in.)
C. Friction material is burned, flaked, or pitted
2. Inspect separator plates (2, Figure 81). Replace if:
A. Scored or galled
B. Tangs are worn or damaged
C. Warpage of coning exceeds 0.25 mm (0.010 in.)
Figure 81
3. Inspect piston inlet seal (1, Figure 82). Replace if

necessary. Hold in place with petroleum jelly.
Figure 82
4. inspect piston (1, Figure 83) for nicks or scratches and

replace if necessary.
Figure 83
Rl 60
,,,.,,:
:i:$$&$=
5. Inspect sealing rings for scratches or grooves. inspect ,.~::g$g&?.
the locks on the ends of rings. Inspect sealing ring
grooves for wear or damage. Replace rings as
necessary. Make sure sealing ring ends are correctly
locked together.
6. Inspect sealing rings patterns in quill for skips, nicks or

scratches.
Figure 84
PARKING BRAKE MOUNTING BRACKET:
1. If mounting bracket P/N 1283 956 Hl or spacer P/N 1283 955 Hl , are damaged in any way, replace them with
mounting bracket P/N 1430 033 Hl. Mounting bracket P/N 1430 033 Hl incorporates the spacer into its design.
61 Rl
REASSEMBLY GENERAL
Refer to appropriate reassembly procedure depending on whether final drive has planetary or non-planetary
reduction. Differential (center section) service is common to both a planetary or non-planetary axle.
- IMPORTANT -
Efficient and successful reassembly of the differential case is dependent on the accomplishment
of a series of specific tasks in the exact order presented in this manual. The block diagram in
Figure 85 shows the order in which these tasks must be completed.
Throughout the Wowing procedures all measurements must be to the nearest. 001” (0.0254 mm).
REASSEMBLY OF MISCELLANEOUS ITEMS
I
+ +
REASSEMBLY OF RING GEAR AND REASSEMBLY OF RING GEAR AND
N&PIN DIFFERENTIAL LOCK/UNLOCK DIFFERENTIAL
+ +
PRELOAD ADJUSTMENT OF NoSPlN PRELOAD ADJUSTMENT OF LOCW

DIFFERENTIAL QUILLS UNLOCK DIFFERENTIAL QUILLS
I I
+
I I
I PINION GEAR CONE POINT ADJUSTMENT
PINION GEAR ENDPLAY ADJUSTMENT

1
piizpq
PINION GEAR INPUf QUILL INSTALLATION
CHECK ROLLING PAlTERN OF RING GEAR

1 AND~ION 1
READJUST CONEPOINT
NO
SHIMS (PINION ENDPLAY
ACCEPTABLE
+ AND BACKLASH MUST
ALSO BE READJUSTED)
I FINAL ASSEMBLY OF DIFFERENTIAL CASE

I
1
REASSEMBLY OF DIFFERENTIAL BRAKE
PISTONS 17319
Figure 85 AXLE ASSEMBLY - SEQUENCE OF TASKS
Rl 62
REASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL
Reassembly of NoSPlN Differential Miscellaneous ltems
1. Install alignment dowels (9, Figure 3) in differential case (20), if removed during disassembly.
2. Install plugs (1, 6, 11, 13, 15,21, and 28, Figure 3) with new O-rings in differential case (20) and cover (7).
3. Install reducer (30, Figure 3) and breather (31) in differential case (20).
4. Install new O-ring (19, Figure 3), bleeder bushing (18) and bleeder screw (17), in differential case (20)
Reassembly of Ring Gear and NoSPlN Differential
1. If ring gear (10, Figure 86) is reused, clean bolt holes in

ring gear. Also, clean ring gear bolts (9).
NOTE: DO NOT use a petroleum base solvent to

degrease bolts and ring gear. USE lacquer
thinner or chlorethane.
2. Using a hot air method, heat ring gear (10, Figure 86) to
a maximum of 300°F (149°C). Install gear on housing
(4) with bolt holes aligned.
3. Apply 3M 2158 Epoxy to lower 0.75 In. (19.050 mm) of

bolt threads.
4. Secure ring gear (10, Figure 86) to housing (4) with flat Figure 86
washers and bolts (9). Tighten bolts to 220 Ibf ft
(30.4 kg-m).
5. Install bearing cones (7 and 8, Figure 86) on housing (4) and cover (3).
6. Pass 5/l 6” threaded rod, 18” Long (1, Figure 86) through housing (4). Then install NoSPlN parts (1 thru 6,
Figure 10) in order shown, on rod (Note differential spider match marks.). When NoSPlN parts are in position
on threaded rod, position cover (3, Figure 86) on rod. Use a 3” O.D. washer and appropriate hex nut (2) on
each end of rod to draw differential assembly parts together.
7. Align cover (3, Figure 86) match mark with differential spider (5) and housing (4).
8. Install bolts (6, Figure 86) to secure housing and cover together. Tighten bolts 85 Ibf ft (11.8 kgem).
9. Once bolts (6, Figure 86) are installed remove threaded rod from differential.
63 Rl
Preload Adjustment of NoSPlN Differential Quills
1. Install bearing cups (8 and 9, Figure 64) in quills (3 and

4) if replacement is necessary.

3. Noting marked position of ring gear on differential case

lower ring gear and differential assembly (1, Figure 64)
into case. It is possible to install ring gear and differential
assembly in case backwards.
4. Install bearing quills (3 and 4, Figure 87) without shims

(5 and 6) into case. Install flat washers and bolts (2).
Tighten bolts holding quill (4) to 66 Ibf ft (9.1 kgem). Only
finger tighten bolts on quill (3).
NOTE: Do not install the one bolt, f/at washer and nut Figure 87
(7, Figure 64) in the unthreaded hole for each
quill. The unthreaded bolt hole is closest to the case opening.
5. Turn differential case (1, Figure 88) with centerline of

differential assembly (2) and quills in a vertical position.
Ring gear side of case must be facing down.
6. Add shims under quill (3) until an endplay reading can be

taken. Tighten bolts holding quill (3) to 66 Ibf ft
(9.1 kgem). Using a dial indicator, measure endplay of
differential assembly. Use a pry bar to lift assembly to
make measurement. Record this measurement. Add
0.002 - 0.005 In. (0.051 - 0.127 mm) to endplay reading.
Subtract combined endplay and preload tolerance from
shim pack to obtain proper preload.
Endplay Measurement
Figure 88
+ 0.002 - 0.005 In,
Combined Endplay and Preload
Shim Pack Thickness Install to Obtain Endplay Reading
Final Shim Pack Thickness
7. Add appropriate shim pack (5, Figure 87) under quill to obtain 0.002 - 0.005 In. (0.051 - 0.127 mm) preload on
bearings. Tighten bolts to 66 Ibf ft (9.1 kgem).
NOTE: The shims are added to this side so when pinion gear is installed the backlash can be adjusted by
moving shims (5, Figure 87) from this side to the other [shims (6)]. This will prevent pinion gear from
jamming into ring gear.
Rl 64
8. Double check shim pack preload by taking a rolling

torque. Rolling torque must be from 2.1 - 7.8 Ibf ft (0.3 -
1.1 kgem).
9. Add shims to decrease rolling torque. Remove shims to

increase rolling torque.
NOTE: When “Backlash Adjustment” is made, shims

will have to be adjusted from one side to the
other.
10. Coat both sides of approximately six ring gear teeth with
“Prussian Blue” or “Never-Seize” compound. Do this at
three locations 120” away from each other. This must be
done so rolling pattern can be check.
65 Rl
REASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL
Reassembly of Lock/Unlock Differential Miscellaneous Items
1. Install alignment dowels (9, Figure 3) in differential case (20), if removed during disassembly.
2. Install plugs (1,6, 15, 21, and 28, Figure 3) with new O-rings in differential case (20) and cover (7).
3. Install reducer (30, Figure 3) and breather (31) in differential case (20).
4. Install new O-ring (19, Figure 3), bleeder bushing (18) and bleeder screw (17), in differential case (20)
Reassembly of Ring Gear and Lock/Unlock Differential
1681
Figure 91
Figure 90
1. Install two sealing rings (1, Figure 90) on differential housing (2). Open rings slightly to install. Make sure rings
are locked once in grooves.
NOTE: Be sure a gap is between locks on ends of sealing rings. Install new rings if not gap is present. Check
new rings for gap.
2. Using a suitable adaptor, press bearing cone (1, Figure

92) onto differential housing (2).
I 17321
Figure 92
Rl 66
3. install seals (1 and 2, Figure 93) into piston bore of
differential housing (ring gear half).
Figure 93
4. Install piston (1, Figure 94) into piston bore of differential

housing (2).
A
WARNING! Do not damage seals when
installing piston.
Figure 94
5. Install three pins (1, Figure 95) in differential piston

housing cover (2), if removed at disassembly.
NOTE: Sprktg (3, Figure 95) will fif over pins when
assembled into housing.
Figure 95
67 Rl
6. Install clutch backing plate, four disk plates and three 1

clutch separator plates (1, Figure 96) into housing (2).
NOTE: The three separatorplates must be between the

four disk plates.
NOTE: Align the internal teeth of the plates with a

straight edge.
7. Place the three springs (3, Figure 96) into position in

housing (2).
Figure 96
8. Using a suitable adaptor, press bearing cone (4, Figure

97) onto cover (2).
9. Aligning splines, position cover (2, Figure 97) into

differential housing (3). Install bolts (1) to hold cover in
place.
10. If ring gear (6, Figure 97) is reused, clean bolt holes in
ring gear. Also, clean ring gear bolts (5).
NOTE: DO NOT use a petroleum base solvent to 168OC

degrease bolts and ring gear. USE lacquer
thinner or chlorethane. Figure 97
11. Using a hot air method, heat ring gear (6, Figure 97) to a maximum of 300°F (149°C). Install gear on housing
(3) with bolt holes aligned.
12. Apply 3M 2158 Epoxy to lower 0.75 In. (19.050 mm) of bolt threads.
13. Secure ring gear (6, Figure 97) to housing (3) with flat washers and bolts (5). Tighten bolts to 220 Ibf ft
(30.4 kgem).
14. Install bevel gear thrust washer (2, Figure 98) and bevel
gear (1) in ring gear side of differential housing (3).
Figure 98
Rl 68
15. Install twenty-six roller bearings (1, Figure 99) in pinion

gear (2).
NOTE: Use petroleum jelly to hold bearings in place.
NOTE: Roller bearings (7) must be rep/aced as a set.
Figure 99
16. Install retaining ring (6, Figure loo), bearing thrust

washer (5), pinion gear (3) with roller bearings (4),
bearing thrust washer (2) and pinion thrust washer (1) on
end of each pinion shaft (7).
I 6823
Figure 100
17. Install pinion shaft assembly (1, Figure 101) on bevel

gear. Align match marks made at disassembly.
18. Align tangs (2) with differential housing slots (3) on each
pinion.
Figure 101
69 Rl
19. install bevel gear (1, Figure 102) on pinion gear set (2).
20. install thrust washer (3) on bevel gear (1).
Figure 102
21 Making sure that match marks aline, position differential

housing (2, Figure 103) on housing (3).
22. Install eight bolts (1, Figure 103) to hold housing halves
together. Tighten bolts 85 Ibf ft (11.8 kgam).
Figure 103
Rl 70
Preload Adjustment of Lock/Unlock Differential Quills
1. Assemble and test differential lock/unlock quill. This is the

sealing ring quill (3, Figure 105).
A WARNING! Inspect for leakage whenever

bearing quill is replaced.
A. Remove old sealant material from quill bore. Clean

outside diameter and bearing quill bore using
chlorethane, lacquer thinner or equivalent. Avoid
handling cleaned surfaces.
B. Following manufactures directions, apply Loctite

#12017 to quill bore where drilled holes break into
bore. Apply a curing primer to bearing cup (1, Figure
104). allow three minutes for primer to dry.
C. Install bearing cup (1, Figure 104) tight against quill

shoulder. Allow 30 minutes for plastic gasket to cure
before test. Figure 104
D. Check for leakage around pressure (inlet) passage

behind bearing cup, by blocking passage (2, Figure 104) using a piece of large O-ring and a pair of locking
pliers. Do not damage surface (3) with locking pliers. Apply a generous amount of clean hydraulic oil
around bearing cup. Use an Air Test Plug and 14.5 PSI (1 kg/cm2) minimum pressure to check for air
leakage. If leakage is present, replace bearing cup and/or quill.
2. Install bearing cup (9, Figure 105) in quill (4), if

replacement is necessary.

4. Noting marked position of ring gear on differential case

lower ring gear and differential assembly (1, Figure 105)
into case. It is possible to install ring gear and differential
assembly in case backwards.
5. Install bearing quills (3 and 4, Figure 105) without shims

(5 and 6) into case. Install flat washers and bolts (2).
Tighten bolts holding quill (4) to 66 Ibf ft (9.1 kgem). Only
finger tighten bolts on quill (3).
NOTE: Do not install the one bolt, flat washer and nut ~%We 105
(7, Figure 705) in the unthreaded hole for each
quill. The unthreaded bolt hole is closest to the case opening.
NOTE: Make sure that oil line port in quill (3, Figure 105) is in proper orientation for installation of oil line.
71 Rl
6. Install adaptors (4 and 5, Figure 106) with new O-rings.
7. Connect fittings (1 and 2, Figure 106) to hold line (3) in

position.
NOTE: Do not tighten fittings until quills are properly

shimmed. This will ensure that no stress is
placed on the connections. Tighten fittings
during “Final Assembly of Differential Case. n
8. Turn differential case (1, Figure 107) with centerline of

differential assembly (2) and quills in a vertical position.
Ring gear side of case must be facing down.
9. Add shims under quill (3, Figure 107) until an endplay

reading can be taken. Tighten bolts holding quill (3) to
66 Ibf ft (9.1 kgmm). Using a dial indicator, measure
endplay of differential assembly. Use a pry bar to lift
assembly to make measurement. Record this
measurement. Add 0.002 - 0.005 In. (0.051 - 0.127 mm)
to endplay reading. Subtract combined endplay and
preload tolerance from shim pack to obtain proper
preload.
Endplay Measurement Figure 107
+ 0.007 - 0.005 In, Preload Tolerance
= Combined Endplay and Preload
Shim Pack Thickness Install to Obtain Endplay Reading
Final Shim Pack Thickness
10. Add appropriate shim pack under quill (3, Figure 107) to obtain 0.002 - 0.005 In. (0.051 - 0.127 mm) preload
on bearings. Tighten bolts to 66 Ibf ft (9.1 kgem).
NOTE: The shims are added to this side so when pinion gear is installed the backlash can be ac@ustedby
moving shims (5, Figure 105) from this side to the other [shims (6, Figure 105)J This will prevent pinion
gear from jamming into ring gear.
Rl 72
11. Double check shim pack preload by taking a rolling

torque. Rolling torque must be from 2.1 - 7.8 Ibf ft (0.3 -
1.1 kg-m).
12. Add shims to decrease rolling torque. Remove shims to

increase rolling torque.
NOTE: When “Backlash Adjustment” is made, shims

will have to be adjusted from one side to the
other.
done so rolling pattern can be check. Figure 108
73 Rl
PINION GEAR CONE POINT ADJUSTMENT
17326
Figure 109
Rl 74
1. Press bearing cup (18, Figure 109) into differential case cover (14).
2. Install perrot or mica braking brake bracket.
A. Mount perrot parking brake bracket as follows;
1) Apply Loctite #505 or #515 to both sides of

brake bracket spacer (25, Figure log), following
manufacturers directions.
2) Align holes and install spacer and parking brake

bracket P/N 1283 956 Hl (5) [at 11.5” from
horizontal center (Figure 1lo)] on differential
case cover (14, Figure 109) with eight flat
washers and bolts (24). Tighten bolts from 45 -
50 Ibf ft (6.2 - 6.9 kgam).
NOTE: On differentials with mounting bracket

P/N 1430 033 HI, apply Loctite #12017 Figure 110
to mounting area of bracket on
differential case cover (14, Figure 109).
Align holes and secure bracket to cover [at 11.5 0from horizontal center (Figure 1lo)] with five
flat washers and bolts. Zghten bolts from 45 - 50 Ibf ft (6.2 - 6.9 kgem). Spacer (25, Figure
109) is not required with this mounting bracket.
B. Mount mica parking brake bracket as follows;
1) Apply Loctite #12017 to mounting area of

bracket on differential case cover (14, Figure
109).
2) Align holes and secure bracket to cover [at 45 o

from centerline (Figure 1lo)] with five f/at
washers and bolts. fighten bolts from 45 - 50 Ibf
ft (6.2 - 6.9 kgem). Spacer (25, Figure 109) is not
required with this mounting bracket.
Figure 111
75 Rl
3. Using a suitable adaptor and arbor press, install bearing cone (23, Figure 109) on pinion gear (10).
- IMPORTANT -
The cone point adjustment procedure presented here is based upon the
precision machining of component parts. No complicated formulas are
required.
4. Subtract number (Figure 112) etched on end of pinion

gear from 8.331 In. (211.607 mm). This will determine
required cone point shim pack thickness to obtain a
proper cone point adjustment.
NOTE: Number etched on end of pinion is in inches.
8.331 In . 1400 Series Constant
Number Etched on Pinion

Gear
= Required Cone Point Shim

Pack
Figure 112
5. Install required cone point shim pack (21, Figure log),
bearing cup (22), and pinion gear (10) with bearing cone
(23) in differential case cover (14).
Rl 76
PINION GEAR ENDPLAY ADJUSTMENT
1. Install bearing cone (17, Figure 109), yoke (13), special washer (8), and castle nut (7) on pinion gear (10).
While rotating pinion gear (lo), tighten castle nut to 445 Ibf ft (61.5 kgam). This will ensure that all bearing
components are properly seated.
NOTE: O-ring (9, Figure 109) and seals (15 and 16) are not installed until after proper pinion gear endplay is
determined.
2. Remove castle nut (7, Figure log), special washer (8), and yoke (13) from pinion gear (10). Press pinion gear
out of bearing cone (17).
3. Install same amount of pinion endplay shims (20, Figure

109) removed at disassembly, washer (19), bearing PINION
cone (17), yoke (13), special washer (8) and castle nut ENDPLAY
(7). Again tighten castle nut to 445 Ibf ft (61.5 kg-m), then SHIMS
loosen it to below 200 Ibf ft (27.7 kgem), and then tighten
it from 225 - 300 Ibf ft (31 .l - 41.5 kg-m). CONE
4. Turn pinion gear (10, Figure 109) using a force of 2 - 4

Ibf ft (0.3 - 0.6 kgem). Then check endplay. Using a dial
indicator apply 23 - 68 Lbs. (10.4 - 30.8 kg) of force to
pinion gear. Endplay reading must be 0.000 - 0.003 In.
(0.000 - 0.076 mm). Adjust pinion endplay shims (20), as
necessary to obtain proper endplay. When proper
”
bearing setting is reached, tighten castle nut so cotter pin

(6) can be installed. Use a different special washer (8) if
necessary to meet torque of 225 - 300 Ibf ft (31 .l -
41.5 kg-m).
-\
kJ
I7
U
GO7HHO4'
Figure 113
NOTE: Each time castle nut and components are
removed to adjust pinion endplay shim pack for
proper endplay, tighten castle nut to 445 Ibf ti (61.5 kgem), then loosen it to below 200 Ibf i?
(27.7 kgem), and then tighten it from 225 - 300 Ibf fi (31.1 - 41.5 kg-m).
5. With proper endplay established, match mark position of castle nut (7, Figure 109) in relationship to yoke (13)
and pinion gear (10).
PINION GEAR INPUT QUILL INSTALLATION AND BACKLASH ADJUSTMENT

done so rolling pattern can be check.
2. Install new alignment dowels (9, Figure 3) in differential

case (1, Figure 114), if replacement was necessary.
3. Secure input quill assembly (2, Figure 114) to case (1)

with fourteen flat washers and bolts (3). Tighten bolts to
229 Ibf ft (31.7 kgem). PO NOT APPLY SEALANT AT
THIS TIME,
Figure 114
77 Rl
4. Install differential backlash tool DR08-111 (4, Figure 114) into splines of NoSPIN.
NOTE: See “‘Special Tools” for backlash tool DRO8-111.
5. Using a dial indicator, measure backlash at 8.250 In. (209.550 mm) from centerline of differential case.
Measure backlash at three points 120” away from each other, and average the results.
NOTE: input yoke must be held stationary and bar moved to measure backlash.
Reading #l
+ Reading #2
+ Reading #3
= + 3 = Average Backlash Reading
6. Differential quill shims (5, Figure 87 or Figure 105) must be adjusted to obtain a 0.007 - 0.015 In. (0.178 -
0.381 mm) backlash.
NOTE: For every 0.001 In. (0.025 mm) of backlash adjustment needed move 0.007 in. (0.025 mm) of shims
from one side to the other. Set differential case on its side when moving shims, this will prevent ring
gear and differential from cocking in quills. Shims are a one piece construction. Quill must be
completely removed, to move and install shims.
7. Tighten differential quill bolts to 66 ibf ft (9.1 kgem).
RING GEAR AND PINION ROLLING PAT-TERN CHECK
The purpose of this procedure is to determine whether pinion

and ring gear teeth are meshing properly.
1. While one person is turning input yoke, a second person

should insert an axle shaft into splines of NoSPIN, and
create a resisting force to load ring gear. With ring gear
“loaded” in this fashion rotate ring gear through at least
one complete pass of coated teeth.
2. Now turn input yoke in opposite direction (and load ring

gear in opposite direction) while rotating ring gear
through one complete revolution.
3. This procedure should have wiped the coating off the

portion of the ring gear teeth (2, Figure 115) that is Figure ,,5
contacting the pinion gear teeth (1).
4. Tooth bearing pattern (3, Figure 115) must start at location (4) 0.120 - 0.520 In. (3.048 - 13.208 mm) from toe
end of pinion.
5. Measure length of tooth pattern (5, Figure 115). It must be a minimum of 1.300 In. (33.020 mm).
Rl 78
6. Adjust cone point shim pack to obtain correct tooth pattern.
7. If rolling pattern is not acceptable, determine whether to add or subtract cone point shims. Then adjust pinion
endplay and backlash.
8. If rolling pattern is acceptable, clean teeth of ring and pinion gears. Then proceed to “Final Assembly” section
of this manual.
FINAL ASSEMBLY OF DIFFERENTIAL CASE
Once a proper cone point adjustment, pinion endplay and backlash are established, the differential case is then
ready for final assembly.
1. Remove differential case cover (input quill) from differential case.
NOTE: Nowinstall one bolt, flat washer and nut (7?Figure 64) in unthreaded ho/e of case for each quill. It is
the bolt hole closest to the case opening.
2. With proper endplay established, match mark position of castle nut (7, Figure 109) in relationship to yoke (13)
and pinion gear (10). Remove castle nut, special washer (8), and yoke from pinion gear so seals (15 and 16)
and O-ring (9) can be installed.
3. Press V-seal (15, Figure 109) into yoke (13).
4. Apply Loctite #12017 to O.D. of seal (10, Figure 109). Press seal into differential case cover (14) with lip
pointing towards bearing cone (17). Press seal into cover just enough to have outside surface of seal even with
edge of chamfer.
5. Apply clean oil to bearing cone (17, Figure 109) to prelubricate it before installation of yoke (13). Coat lip of seal
(16) with oil.
6. Aligning match marks, install yoke (13, Figure log), O-ring (9), special washer (8) and castle nut (7). Tighten
castle nut from 225 - 300 Ibf ft (31.l - 41.5 kg*m) making sure match marks align. Install cotter pin (6) to secure
nut into position.
7. LOCWUNLOCK DIFFERENTIAL ONLY - Tighten fittings on oil supply line. See Figure 106.
8. Position two O-rings (10, Figure 3) in grooves of differential case face.
9. Apply Loctite #515 face of differential case face and position differential case cover (14, Figure 109) into
position. Install fourteen flat washers (4, Figure 3) and bolts (3, Figure 3). Tighten bolts to 229 Ibf ft (31.7 kgmm).
10. Secure brake disk (12, Figure 109) to yoke with eight flat washers and bolts (11). Tighten bolts from 45 - 50
Ibf ft (6.2 - 6.9 kg-m).
79 Rl
REASSEMBLY OF DIFFERENTIAL BRAKE PISTONS
GO4AVOO
rlgure i IO
NOTE: The brake portion of the axle assembly has several versions of pistons, brake discs
and backing plates.
Always refer to the appropriate parts manual for serial number ranges and parts break down.
NOTE: Coat all components with clean hydraulic oil before installation.
1. Install inner seal (4, Figure 116) and outer seal (5) in each side of differential case (3).
2. Install three dowels (2, Figure 116) and piston (1) in each side of differential case (3).
3. Restrain piston (1, Figure 116). Connect a 600 PSI (42.2 kg/cm2) air gauge and a shutoff
valve to brake line
port in differential cover. Apply 100 PSI (7.0 kg/cm2) of air pressure to brake piston and
close valve. The
pressure gauge should remain at 100 PSI (7.0 kg/cm?. If it does not, check piston seals and/or
O-ring (located
between cover and case).
Ri 80
REASSEMBLY OF NON-PLANETARY CARRIER
1. Install bearing cup (1, Figure 117), bearing cone (2) and
grease seal (3) in outboard end of final drive housing (4).
NOTE: Lip of grease seal must point out. See cross

sectional drawing Figure 12.
2. Install bearing cup (5, Figure 117) in inboard end of final

drive housing (4).
3. Install grease fitting (6, Figure 117) in side of final drive

housing (4).
NOTE: A rollover stand is used to bolt the tandem

sleeve to during this service procedure. The I
stand allows access to both ends of the final Figure 117
drive assembly.
4. Install oil seal (1, Figure 118) in flanged end of tandem

NOTE: Lip of oil seal must point in. See cross sectional
drawing Figure 12.
I GO7HHOO:
Figure 118
5. Set tandem mounting sleeve (1, Figure 119) on end with

flanged end down.
6. Using a suitable lifting device, lower final drive housing

(2, Figure 119) onto tandem mounting sleeve (1).
7. Install bearing cone (3, Figure 119) on tandem mounting

sleeve (1).
Figure 119
81 Rl
8. Install two studs (1, Figure 120) as guide pins, and

position bearing retainer (2) (without O-ring) on end of
tandem mounting sleeve.
9. Install four bolts (3, Figure 120) at 90” to each other

finger tight.
10. Slowly and in even increments tighten four bolts (3,

Figure 120) to 200 Ibf in (2.3 kgem), while rotating final
drive housing (4). Loosen bolts to 0 Ibf in (0.0 kgem), and
then again tighten them to 130 Ibf in (1.5 kg=m), while
rotating housing.
NOTE: Rotating housing will ensure that all bearing

components are properly seated. Figure 120
11. Using a depth micrometer (1, Figure 121), measure from

outside face of bearing retainer plate (2) to end of
tandem mounting sleeve. Do this at two places opposite
each other and average readings.
Depth Micrometer
Reading One
+ Depth Micrometer
Reading two
+2= Average
Depth Micrometer Figure 121
Reading
12. Remove bearing retainer (2, Figure 121) and measure its thickness in locations of depth micrometer readings.
Average these two readings. Subtract average thickness of bearing retainer from average depth micrometer
reading to obtain required shim pack thickness.
Thickness Reading One
+ Thickness Reading two
= + 2 = Average Thickness Reading
Average Depth Micrometer Reading
= Required Shim Pack Thickness
Rl 82
13. Using a grease gun, pack inner bearing (1, Figure 122)
with grease before installing shims (2) and bearing
retainer. Be careful not to get grease into retainer plate
mounting holes.
14. Install required shim pack (2, Figure 122).
Figure IZZ
15. Install O-ring on O.D. of bearing retainer (1, Figure 123).
16. Install retainer plate (1, Figure 123) on alignment studs

(2).
17. Install and tighten bolts (1, Figure 124) to values listed
here. Remove alignment studs.
A. If sixteen bolts (P/N 24540Rl) are used, tighten

them from 40 - 45 Ibf ft (5.5 - 6.2 kg*m)
B. If eighteen bolts (P/N 31148Rl) are used, tighten

them to 50 Ibf ft (6.9 kgem).
NOTE: Following manufacturer’s directions, apply

Loctite #242 to bolt threads.
18. Pump tandem sleeve assembly (2, Figure 124) full of

grease. Slowly rotate final drive housing while filling.
Continue to fill with grease until it passes grease seal at Figure 124
tandem sleeve flange (3).
NOTE: Refer to “Operation and Maintenance Manual” forproper grease specification.
83 Rl
19. Install output shaft sleeve (1, Figure 125), spherical roller
bearing (2), output sprocket spacer (3) (with small O.D.
towards sprockets) and two output shaft sprockets (4
and 5), on axle shaft (6). Install retaining ring (7) to
secure components on shaft.
NOTE: Bossed end of two sprockets most face each

other.
NOTE: Appk a moly-lithium based grease to splines of

axle shaft and output shaft sprockets.
I GO7HHOH
Figure 125
20. Install axle assembly (1, Figure 126) in tandem mounting

sleeve (2). Secure it in place with retaining ring (3).
21. Install locating dowels (1, Figure 127) in final drive

housing (2).
22. Coat final drive housing (2) flange with Loctite #518
Master Gasket, following manufacturer’s directions.
Figure 127
Rl 84
23. Identify brake backing plate, brake disk and piston to be installed.
There have been several versions of brake assemblies released. These assemblies must be identified for
proper assembly and operation of brakes. Use the following table along with the latest parts manual to identify
parts.
If axle assembly has been previously serviced, newer component parts may have already been substituted.
VERSION OF AXLE PART NUMBER BRAKE PISTON, DISK AND

INTERNAL WET BACKING PLATE
BRAKE NON-PLANETARY PLANETARY
VERSION #l 1431168H91 1431169H91
NOTE: Version #3 NOTE: Version #2 NOTE: If version #2

and #4 parts can brake parts may be parts are used to
not be used to used to service this service this axle,
service version #1 axle. backing plate P/N
and #2. 1431599H91 must be
used.
Version #l and #2
use dowel pins to I 1,331
prevent the piston 127741 lH91 1277412H91

and backing plate The brake piston (1) has three
from rotating. NOTE: Version #2 NOTE: If version #2 dowel holes.
brake parts may be parts are used to
used to service this service this axle, The brake disk (2) has slots.
axle. backing plate P/N
1431599H91 must be The backing plate (3) has three lugs
used. on the circumference. The plate is
also counterbored for planetary
gear clearance.
VERSION #2 1277411 H92 1277412H92
NOTE: Version #3
and #4 parts can
not be used to
service version #I
and #2.
Version #I and #2
use dowel pins to
prevent the piston
and backing plate
The brake piston (1) has three
from rotating.
dowel holes.
The brake disk (2) has no slots.
The backing plate (3) has three

slotted luas on the circumference.
85 Rl
VERSION OF AXLE PART NUMBER BRAKE PISTON, DISK AND

INTERNAL WET BACKING PLATE
BRAKE NON-PLANETARY PLANETARY
VERSION #3 1431781 H91 & H92 1431782H91 & H92
NOTE: Version#l
and #2 parts can
not be used to
service version #3
and #4.
Version #3 and #4
use lugs on the
circumference of 1432004H91 & H92 1432005H91 & H92
the piston and
-he brake piston (1) has one lug.
backing plate to
prevent them from
-he brake disk (2) has no slots.
rotating.
-he backing plate (3) has two lugs
rn the circumference with no dowel
rins.
VERSION #4 1431781 H93, H94 & 1431782H93, H94 &

UP UP
NOTE: Version #l
and #2 parts can
not be used to
service version #3
and #4.
Version #3 and #4
use lugs on the
1432004H93, H94 & 1432005H93, H94 &
circumference of
the piston and UP UP
-he brake piston (1) has one lug.
backing plate to
prevent them from
-he brake disk (2) has no slots.
rotating.
-he backing plate (3) has two lugs
rn the circumference with two
lowel pins
Rl 86
24. Note position of three brake backing plate dowels (1 thru

3, Figure 132) in spacer (4) in relationship to final drive
mounting pads, and install spacer on final drive housing
(5).
NOTE: Position of brake backing plate dowels is critical.
If they are not properly positioned, the final drive
assembly will not bolt up properly to the
differential case. There are reliefs in the
differential case designed to accept backing
plate.
NOTE: On later built axles the spacer (4) is cast as an

integral part of the housing (5). The one piece L
spacer/housing and the separate spacer and Figure 132
housing are available from the parts
department. In the event that a one piece
spacer/housing in not available a separate housing and spacer may be substituted, along with an
additional two locating dowels.
25. Install backing plate dowels (1 thru 3, Figure 132) in spacer (4).
26. Install a retaining ring (1, Figure 133) in one groove of

brake plate gear (2). Set friction disc (3) in position on
the brake plate gear and install remaining retaining ring
(4) in second groove.
Figure 133
27. For units S/N 200502 & Up.
The backing plate may or may not have dowel pins

pressed into it. If it does have dowel pins, press them out
of backing plate as shown.
A. Long dowel (Dimension ‘IX,” Figure 134) must

protrude 0.925 kO.039 In. (23.5 +l mm).
B. Short dowel (Dimension “Ytn Figure 134) must

protrude 0.236 10.039 In. (6 +l mm).
NOTE: The brake portion of the axle assembly has

several versions of pistons, brake discs and
backing p/Z&S. A/Ways refer t0 the apprOpr&tS Figure ,34
parts manual for serial number ranges and parts
break down.
87 Rl
28. Set backing plate (1, Figure 135) into position on dowels
(2).
29. Position friction disc and brake plate gear assembly (3,
Figure 135) on backing plate (1) and axle shaft (4).
Figure 135
30. install locating dowels (1, Figure 136) in differential case

(2).
31. Following manufacturer’s directions, apply Loctite #518

Master Gasket to flange.
‘igure 136
32. Sling final drive assembly (1, Figure 137) and position it
against differential case (2). install flat washers and bolts
to secure tandem sleeve assembly into position. Tighten
bolts from 210 - 225 Ibf ft (29.0 - 31 .l kgem).
Figure 137
Rl 88
REASSEMBLY OF PLANETARY CARRIER
1. The final drive tandem sleeve reassembly portion of this section is the same as non-planetary carrier. Follow
“Reassembly of Non-Planetary Carrier” Steps 1 thru 18, for assembly procedures.
2. Install locating dowels (1, Figure 138) in final drive

housing (2).
3. Coat final drive housing (2, Figure 138) flange with

Loctite #518 Master Gasket following manufacturer’s
directions.
NOTE: A rollover stand (shown in background) is used

to bolt the tandem sleeve to during this service
procedure. The stand allows access to both
ends of the final drive assembly.
Figure 138
4. Note position of three brake backing plate dowel pin

holes (1 thru 3, Figure 139) in ring gear (4) in
relationship to final drive mounting pads (5), and install
ring gear on flange (6).

If they are not properly positioned, the final drive
plate.
Figure 139
89 Rl
5. Install retaining ring (1, Figure 140) on planet carrier (2).
6. Install bearing spacer (3, Figure 140) with twenty-four

roller bearings (4) on each side of it in planet pinion gear
(5).
NOTE: A light coating of grease in bore of planet gear

will help hold roller bearings in position.
7. Place a thrust washer (6, Figure 140) on each side of

planet pinion gear (5). Slide thrust washers and gear
assembly into carrier (2).
8. Install planet shaft (7, Figure 140) into carrier and planet -
m7taion
gear assembly with retaining groove towards retaining Figure 14o
ring. Engage retaining ring in planet shaft groove.
Repeat Steps 6 thru 8 for remaining planet gears.
NOTE: To aid assembly slide retaining ring opening around carrier as each shaft is installed.
9. Install planetary spacer (1, Figure 141) and carrier

assembly (2) on axle shaft (3).
I GO7HHOZC
Figure 141
10. Position a thin sheet of plastic (1, Figure 142) inside the
tandem mounting sleeve (2) to protect oil seal when axle
shaft is installed. Coat plastic sheet with clean oil to help
aid installation.
G07HH02:
Figure 142
Rl 90
11. Using a suitable lifting eye and sling, lower planetary

carrier and tandem axle assembly (1, Figure 143) into
final drive assembly (2) engaging planet gears (3) with
ring gear (4).
12. Carefully remove plastic sheet (1, Figure 142) from

between axle shaft and oil seal. DO NOT CURL LIP ON
SEAL.
Figure 143
13. Install thin brass thrust washer (not shown), retaining

washer (1, Figure 144) and bolt (2), to secure carrier (3)
to axle shaft. Place a brass bar (4) between planet gear
teeth and ring gear as shown. Then tighten bolt (2) from
600 - 650 Ibf ft (83.0 - 89.9 kgem).
Figure 144
14. Install a piece of bar stock (1, Figure 145) as shown, to

hold planet carrier (2) and ring gear (3) in position. Then
turn assembly over.
Rl
15. Install spherical roller bearing (1, Figure 146) in tandem

mounting sleeve (2). Secure it in position with retaining
ring (3).
16. Install output sprocket spacer (4, Figure 146) on axle (5).
Figure 146
17. Install output shaft sprocket (1, Figure 147) on axle (2).
Secure sprocket in place with retaining ring (3).
NOTE: Apply a moly-lithium based grease to splines of

axle shaft and output shaft sprocket.
Figure 147
18. Turn final drive assembly back over and remove bar
stock used to retain carrier (1, Figure 148) and ring gear
(2).
19. Install triangular lock plate (3, Figure 148) to lock, bolt (4)
into position.
Figure 148
Rl 92
20. Install retaining ring (1, Figure 149) in sun gear (2).
21. Slide input shaft (3, Figure 149) into sun gear (2).
Figure 149
22. Install sun gear (1, Figure 150) with input shaft (2) in
carrier (3).
23. install three brake backing dowels (4, Figure 150) in ring
gear (5).

If they are notproperly positioned, the final drive
plate.
Figure 150
24. Install backing plate (1, Figure 151) in position on dowels

(2).
25. Place friction disc (3, Figure 151) on backing plate (1)
and sun gear (4).
Figure 151
93 Rl
26. Install locating dowels (1, Figure 152) in differential case

(2). Coat flange with Loctite #518 Master Gasket
following manufacturer’s directions.
Figure 152
27. Sling final drive assembly (1, Figure 153) and position it
against differential case (2). Install flat washers and bolts
to secure tandem sleeve assembly into position. Tighten
bolts from 210 - 225 Ibf ft (29.0 - 31 .l kpm).
Figure 153
Rl 94
INSTALLATION
1. Position final drive assembly (1, Figure 154) under

grader. Using a suitable lifting device and spreader, sling
final drive assembly as shown. Position a jack under
brake disc (2) to prevent tipping of final drive as it is
raised into position, against frame (3).
NOTE: See “Special Tools” for manufacturing details of

spreader bar and chains.
2. Install eight washers and bolts (6, Figure 154) that

secure final drive to frame.
NOTE: Torque bolts to 580 Ibf fi (80.2 kgem).
3. Connect drive shaft (4, Figure 154) to input yoke (5). Figure 154
NOTE: Torque bolts from 45 - 50 Ibf ft (6.2 - 6.9 kgem).
4. Check drain plug to ensure that it is properly installed.

Remove fill plug and add oil to proper level. Refer to “Operation and Maintenance Manual” for proper lubricant
and capacity.
5. Install new O-ring (4, Figure 155) on each fitting (2), if

replacement was necessary.
6. Install a fitting (2, Figure 155) in each side of final drive

(3). Unplug and connect brake hoses (1) to fittings as
tagged during removal.
NOTE: If unit is equipped with a locklunlock differential,

connect supply and return lines as tagged
during removal. Plug and cap hoses and fittings.
Figure 155
95 Rl
7. Install parking brake caliper now.
A. Perrot parking brake caliper installation.
1) Slide caliper (5, Figure 156) over parking brake

disc and align mounting holes with parking
brake bracket (11). Install a bolt (14), nut (13)
and cotter pin (12), in each end of caliper.

2) Refer to “Parking Brake Adjustment” section of

this manual for proper adjustment procedure.
NOTE: If hose leading to parking brake caliper I 17326
was disconnected, the caliper will have Figure 156

to be bleed, See “Parking Brake
Bleeding” section of this manual.
3) Slide washer (9, Figure 156) on bolt (10). Repeat for other bolt. Slide a bolt in each end of support bar
(6). Slide one spacer (8) on each bolt. Position bolts in mounting bracket (11). Install flat washer and
nut (7) on each bolt. Only finger tighten nuts at this time.
4) Install bolt (4, Figure 156) in center hole of support bar (6), far enough to install jam nut (1) on bolt,
half way up threads. Screw bolt into threaded hole in caliper (5), until jam nut makes contact. Tighten
jam nut. Align support bar and tighten its mounting hardware so bolt (4) passes freely through center
hole of bar. Tighten two bolts (10) to 45 Ibf ft (6.2 kgem).
5) Loosen jam nut (1, Figure 156) and remove bolt (4) from caliper (5). Remove jam nut from bolt and
remove bolt from support bar (6). Slide washer (3) and spring (2) on bolt. Place bolt back into center
hole of support bar. Install jam nut on bolt, positioning it at top of threads. install bolt in threaded hole
in caliper.
6) Turn bolt (4, Figure 156) in until washer (3) and spring (2) just touches support bar (6) and bolt head.
Spring should be at its free length (no compression). Then turn bolt in three more revolutions and lock
jam nut.
Rl 96
B. Mica parking brake caliper installation.
1) Install four bolts, eight flat washers and four hex

nuts (1, Figure 157) to secure caliper mount
assembly (2) with caliper (4) to parking brake
bracket (3). Tighten bolts from 100 - 110 Ibf ft
(13.8 - 15.2 kgem)
2)
between caliper pads.
Refer to “Parking Brake Adjustment” section of

this manual for proper adjustment procedure.
NOTE: If hose leading to parking brake caliper Figure 157

was disconnected, the caliper will have
to be bleed. See “Parking Brake
Bleeding” section of this manual.
8. Turn parking brake release valve (1, Figure 158) fully

CCW to open it.
9. Disconnect port-a-power or other auxiliary pumping

device from quick connect fitting (2, Figure 158)
Figure 158
10. Prepare mating surfaces of tandem case (1, Figure 159)

and final drive with Loctite #518 Master Gasket, following
manufacturer’s directions.
NOTE: Thoroughly clean surface to be sealed with

degreasing solvent. Apply primer “N” (spray
can-accelerator) liberally to one surface to
shorten curing time. Apply gasket-sealant as
required to other surface. Assemble without
excessive lateral movement.
11. Apply Loctite #518 Master Gasket to all bolt threads,

following manufacturer’s directions.
Figure 159
97 Rl
12. Install seven washers and bolts that secures final drive and tandem case (1, Figure 159) together, into tandem
mounting sleeve. With seven bolts in a row, rotate tandem mounting sleeve until they are located at the top of
sleeve under frame.
13. Using a 2 Ton (1814.4 kg) lifting device, sling tandem case (1, Figure 159) as shown.
14. Position tandem case against final drive assembly, aligning tandem mounting sleeve with tandem case. Install
remaining seventeen washers and bolts to secure tandem to final drive.
NOTE: Torque all twenty-four bolts to 750 Ibf ft (20.7 kgem).
A WARNING! Position jacks under tandem case to prevent rocking.
15. If removed, install chains into tandem case by lowering

them over axle sprockets and bringing them up over
center drive sprockets (Figure 160).
Figure 160
16. Rotate tandem axle assembly until master link (1, Figure
161) can be installed through side access hole. Install
master link in chain (2) with cotter pin side towards
center of tandem case.
NOTE: There are two different types of chains used in

the tandem case. A double strand chain is used
with a non-planetary axle. Single strand chain is
used with a planetary reduction axle. The
master links and components for these chains
are shown in Figure 162 and Figure 163.
16371
‘igure 161
Rl 98
Figure 162 DOUBLE STRAND CHAIN MASTER Figure 163 SINGLE STRAND CHAIN MASTER
LINK (NON-PLANETARY AXLE) LINK (PLANETARY REDUCTION AXLE)
17. Install four side access hole covers (4, Figure 164) and
two top access hole covers (5) on tandem case.
NOTE: Seal access covers with Loctite #518 Master

Gasket, following manufacturer’s instructions.
18. Be sure drain plug (3, Figure 164) is securely in place

and fill tandem case (2) with 8.7 U.S. Gallons (32.9 o) of
oil. Refer to “Operation and Maintenance Manual” for
proper lubricant and specification.
NOTE: App/y Loctite #592 following manufacturer’s

directions, too drain plug and oil level plug.
19. Leave jack and blocking (1, Figure 164) under tandem Figure 164
case.
20. Using a suitable lifting device and tire tongs, position tire
on wheel, and secure in place with eight wheel clamps
and lug nuts (1, Figure 165). Tighten lug nuts to 115 Ibf
ft (15.9 kgem).
21. Repeat procedure for remaining tires.
A
WARNING! Make sure that tires are
properly center. Refer to “Rim
Centering” section of “Operation and
Maintenance Manual” for instructions.
22. Remove blocking from under unit once remaining

tandem and tires are installed.
Figure 165
99 Rl
23. Position transmission guard (1, Figure 166) on suitable

floor jack, and raise into position. Secure guard to frame
with two bolts (2), lock washers (3) and hex nuts (4) on
each side and four bolts (5), lock washers and hex nuts
on rear.
24. Remove jack.
25. Fill tandem cases and final drive with appropriate

lubricants. Refer to “Operation and Maintenance Manual”
for lubricants and capacities.
Figure 166
Rl 100
SHOP MANUAL H-03.OOK
RI
CIRCLE ADJUSTMENT (FOUR SHOE)

CAUTION
ALL JACKING, HOISTING AND GENERAL WORKSHOP

EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE
IN GOOD WORKING ORDER.

INJURY.
KOMATSU DRESSER COMPANY 850 SOUTH STREET GALION, OH 44833
0695
Refer to “General Torque Values” shop manual section when SPECIFIC TORQUES are not given in this shop
manual section. All values listed throughout this manual are lubricated (WET) unless stated otherwise.
METRIC CONVERSIONS
SHOP MANUAL SECTION H-03.00K
TABLE OF CONTENTS
CONTENTS PAGE
INTRODUCTION ................................................. 1
REBUILDING TEETH ............................................. 3
VERTICAL ADJUSTMENT .......................................... 4
PINION ADJUSTMENT ............................................ 5
INTRODUCTION
This section is written as a guide to properly adjust the drawbar and circle operating clearances. The adjustment
will be made to the vertical mounting shoes and the circle pinion gear. There are two major contact points on the
mounting shoes. The top of the shoes provide a horizontal bearing surface for the circle (A). The edge of each shoe
opposite the jack bolts provide a vertical bearing surface for the circle (B).
:K BOLT
15369
3gure 1
The number of shims used with each vertical mounting bolt determines the overall clearance at point (C). A gap,
no less than .03125 In. (0.793 mm) and no more than 0.0625 In. (1.588 mm), must be maintained between the
bottom of the drawbar and top of the circle at this point to ensure no binding when the circle is rotated. This
clearance will be measured at areas directly above the four shoes.
After completing the adjustments in this section, the gap running the length of each bearing surface (A & B) should
be consistent. The shoes should be adjusted for proper alignment before tightening vertical bolts. Improper
alignment at surface (B) on any shoe will cause uneven wear. Each shoe should be of equal distance from the
vertical edge of the circle. The shoe clearance at (A) should be consistent throughout its length. (A & C) are the
same depending on whether or not the blade is in the air.
Rl
The adjustments detailed here were performed on new equipment. Variables may appear in this procedure as
equipment components become worn through work.
A WARNING! Do not remove all the vertical bolts from the shoes at the same time. The shoe is
very heavy and will cause injury if it falls from the mounting bolts.
REBUILDING TEETH
At times it may become necessary to rebuild circle teeth due to excessive circle to shoe play, either by breaking
a tooth or hitting an object which is firmly planted in the roadbed, such as waste concrete or a manhole cover. By
far, circle rebuild is less expensive, unless the circle is out of round, then premature shoe wear or repeated tooth
breakage will be evident. To repair a mainline grader drawbar circle which has a broken tooth or teeth, use the
following procedure:
1. Remove the circle from the drawbar.
2. Clean the area to be repaired by grinding until a good base is reached.
3. Build-up the tooth by welding to within 0.250 In. (6.350 mm) of the original tooth profile, using E-7018
electrodes or equivalent. A profile gauge can be made from an adjacent tooth.
4. Build-up the remaining 0.250 In. (6.350 mm) of tooth using a hard-surfacing electrode E-19141 or equivalent.
This tooth should be built up oversize and reduced to size by grinding.
Rl 2
VERTICAL ADJUSTMENT
A
WARNING! Do not remove all
VERTICAL
the vertical bolts from the
UNTING BOLT
shoes at the same time. The
EACH SHIM IS
shoe is very heavy and will l/32” MIN. l/32” THICK
cause injury if it falls from the I-
l/16” MAX.
mounting bolts. , $DRAWBAR
CIRCLE i@Yjk
SHOE #I: Set parking brake. With moldboard .-L JACK BOLT
set crosswise under grader, apply slight down
pressure with the blade lift controls.
SHOi
With moldboard in this position, the gap at CAUTION: DO NOT Remove All Mounting
shoe #I, between the bottom of the moldboard Bolts At Same Time.
plate and the top of the circle, should be
0.312 In. (7.925 mm) minimum to 0.062 In. 15370
(1.575 mm) maximum.
Figure 2
If the clearance in this area is less than
0.312 In. (7.925 mm) or greater than 0.062 In. (1.575 mm), shims should be added to or removed from each bolt.
Removing/adding one shim from each bolt will decrease/increase the gap 0.312 In. (7.925 mm).
SHOES #2 THRU #4: Raise moldboard 1 .OOOIn. (25.400 mm) from the ground. Measure the clearance at shoes
#2 thru #4. After measuring the gap, slight down pressure should be applied to the moldboard before adding or
removing shims.
When the blade in the air, the circle tips or tilts (usually) such that an air gap occurs at (C) on shoes #2 thru #4
and also occurs at (A) on shoe #l .
A WARNING! When adding or removing shims,

grader with slight down pressure applied.
the moldboard should be crosswise under the
Do not torque vertical bolts at this time. It is necessary for the shoes to be moveable in order to perform the pinion
adjustment.
Rl

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G-01 .

FRONT AXLE ASSEMBLY

GD530A-1 200417 & Up

ALL JACKING HOISTING AND GENERAL WORKSHOP

EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

SAFE WORKSHOP PRACTICES ARE A MUST.

FOR TABLE OF CONTENTS SEE PAGE 1

KOMATSU DRESSER COMPANY 850 SOUTH STREET GALION, OHIO 44833

3gure 1 EXPLODED VIEW OF NON-ALL WHEEL DRIVE FRONT AXLE ASSEMBLY

LEGEND FOR NON-ALL WHEEL DRIVE FRONT AXLE

1. FRONT AXLE WELDMENT 33. FLAT WASHER

LEGEND FOR ALL WHEEL DRIVE FRONT AXLE

1. GEARBOX - L.H. (SEE APPROPRIATE SHOP 29. BUSHING

FRONT AXLE TORQUE VALUES

is a comprehensive listing of special torques used during overhaul of this component.

RIM TO WHEEL NUTS

FRONT AXLE TO FRAME PIVOT PIN CAPS

STEERING YOKE TO AXLE

LEANING WHEEL CYLINDER &TIE BAR

TESTS AND ADJUSTMENTS

FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT

1. Steering cylinders to be equal length.

A. Factory production set at 24.000 In. (609.600 mm)

B. Field check - measurement from hex end of

1) Loosen jam nut (I, Figure 9) on ball socket

2) The steering cylinder ball socket assembly (with Figure g

4) Repeat Steps 1 .B.l) thru 1 .B.3), for other steering cylinder.

1. Park grader on a “LEVEL” concrete surface. Make sure

2. Using steering wheel and leaning wheel cylinder control

3. Check and adjust front wheel “Toe In,” if necessary.

All Wheel Drive - 0.0 In. (0.000 mm) I_- FRONT _I

A. Measure the distance between the wheels of the

NOTE: Do not measure on tires or tire rims. Due to

B. NON-ALL WHEEL DRIVE AXLE ONLY: The 15359

D. If front wheels need alignment, loosen jam nut (1,

F. Once the proper alignment is obtained, tighten the

4. Synchronize steering cylinders:

A. Disconnect L.H. steering

from L.H. steering arm.

B. Steer machine right so rod

C. Match mark rod end of L.H. EXAMPLE:

NOTE: Very carefully count

NOTE: Record the direction

E. Divide number of turns above

NOTE: The result is the

5. Re-tighten all lock nuts.

1. Remove grease zerk (I, Figure 14) from bottom of

2. Remove both ends of tie rod assembly (1, Figure 15) by

NOTE: On some axle assemblies, there may not be a

4. Have another person position suitable blocking (1,

A WARNING! Use extreme care

6. Tag and match mark hoses (1, Figure 18) to steering

7. Tag and match mark hoses (1, Figure 19) to leaning

8. ALL WHEEL DRIVE AXLE ONLY: Refer to

9. Using a suitable lifting device, sling axle assembly (1,

NOTE: When removing rearpivot cap, remove locating

11. Lower axle assembly and remove from machine. Place

6. Remove self-locking nut (1, Figure 25) and flat washer

7. Supported by sling and overhead hoist, remove self-