Assembly

ASSEMBLY




175MM FIA Front Axle Exploded View







DIFFERENTIAL/RING GEAR ASSEMBLY





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




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




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




4. Using Installer 9666 (1), install new differential side bearing (ring gear side).




5. Using Installer 9665 (1), install new differential side bearing (opposite side).

PINION HOUSING ASSEMBLY





1. Using Handle C-4171 (2) and Installer D-129 (1), press new pinion head bearing cup (3) into pinion gear housing.




2. Using Handle C-4171 (1) and Installer D-130 (2), press new pinion tail bearing cup into pinion gear housing.




3. Using Installer L-4507, install new pinion head bearing.




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




5. Install pinion gear/bearing assembly into pinion housing. Using Installer L-4507 (1), press new pinion tail bearing (2) onto shaft.




6. Using Installer 9677 (1), install new pinion seal.




7. Using Installer L-4507 (1), install pinion flange (2) until it bottoms.




8. Using Spanner Wrench 6958 (2), install pinion flange nut and torque to 475 Nm (350 ft. lbs.).




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




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

AXLE HOUSING ASSEMBLY





1. Using Installer L-4507 (1), install new axle seal (inner) (2) into housing.




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




3. Using Handle C-4171 (4) and Installer D145 (3) press new side bearing cup (2) into housing (1) until it bottoms.




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




5. Using Handle C-4171 and Installer D-129 (1), press new side bearing cup into cover until it bottoms. Use suitable cup (3) to support and protect cover.




6. Install differential/ring gear assembly (3), new cover O-ring seal (4), and cover (5).
7. Install and torque cover-to-housing bolts to:

- M10x40 - 65 Nm (48 ft. lbs.)
- M8x25 - 34 Nm (25 ft. lbs.)





8. Using Torque Tool C-4995 (1), measure differential side bearing rotating torque (preload). Rotating torque should be within 190 - 250 N. cm (17 - 22 in. lbs.).




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




10. Install new pinion housing O-ring seal (1).




11. Install pinion housing assembly into axle housing with proper pinion depth shim (1).




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