Disassemble/assemble differential

AR35.30-B-0465SP

Disassemble/assemble differential

02.01.2020

Rear axle

772.117 in model 979.272/277

with code A59 (Rear axle Meritor MS 06.11x3)

with code A74 (Meritor rear axle self-locking differential)

Modification notes

19.12.2019

Clearance between ring gear/pinion

BE35.31-B-1001-03SP

1

Pinion nut

2

Plain washer

3

Coupling flange

4

Deflector

5

Retainer

6

Outer tapered roller bearing

7

Outer tapered roller bearing race

8

Differential housing

9

Spacer

10

Wedges

11

Inner tapered roller bearing race

12

Inner tapered roller bearing

13

Pinion

14

Bearing cap

15

Bearing cap bolt

16

Adjustment threaded ring (ring gear side)

17

Tapered roller bearing race

18

Tapered bearing

19

Differential box

20

Ring gear bolt

21

Sprocket

22

Planetary gear

23

Retainer ring

24

Spring

25

Driven clutch disc

26

Crosshead

27

Differential case cover

28

Bolt of the differential case cover

29

Tapered bearing

30

Tapered roller bearing race

31

Adjustment ring



Disassemble

1

Drain the oil



.

AP35.00-B-3501SP

2

Remove the differential carrier assembly (8) from the axle housing

.

AR35.30-B-0432SP

3

Mark the bearing caps (14) and the differential carrier housing (8)

 The marks must be clearly visible.
Use a punch pin to make the marks.

4

Check the backlash of the ring gear (21) and pinion (13)

.

AR35.30-B-0475SP


To ease the assembling:
Check the backlash and write down the found values.

.Clearance between ring gear/pinion

*BE35.31-B-1001-03SP

5

Remove the bearing caps (14), the adjustment threaded rings (31, 16), and the inner tapered roller bearing races (30, 17)

6

Remove the differential case assembly

.

AR35.30-B-0464SP

 Use a suitable lifting device.

7

Pull out the tapered roller bearings (29, 18)

.

AR35.30-B-4301-01SP

8

Install the set of containment bolts and washers of the self-locking differential


Do not loosen the fastening bolts of the differential case (28) before installing the set of containment bolts and washers of the self-locking differential:
The self-locking assembly is under spring tension (24), and when removing the fastening bolts of the differential case (28), this can cause serious personal injuries.

9

Remove the fastening bolts of the differential case cover (28) and the differential case cover (27) from the ring gear (21)

10

Remove the full self-locking assembly

11

Release the containment bolts and the washers

To relief the springs tension (24):



Slowly loosen the containment bolts and washers.

12

Remove the planetary gears (22), the retaining rings (23), the springs (24), the set of driven clutch discs (25), and the spider (26)

13

Remove the ring gear (21) from the differential case housing (19)

.

AR35.30-B-4300-04SP

14

Remove the drive pinion (13)

.

AR35.30-B-0458SP



Clean

15

Wash all components thoroughly

To prevent corrosion, risks or oxidation on the parts:



Wash with a clean non-flammable solvent and dry the components.



Check

16

Check the splines of the driven clutch discs (25)

If the splines have permanent damages:



The complete set of clutch discs must be replaced.

If the driven clutch discs present burrs or small chippings (25):



Burrs and small chippings must be removed using an abrasive stone or a small grinding machine.

17

Check the teeth of the driven clutch discs (25)

It they are worn:



Replace the complete set.

18

Check the retaining rings (23);

Check the retaining ring tabs for breakage or wear, if necessary:



Replace the complete set.

19

Check the teeth on the spider (26) and on the central cam

 The central came must have free motions.

If it presents wear or chipping:



Replace the complete set.



Install

20

Install the pinion (13)

.

AR35.30-B-0458SP

21

Install the ring gear (21) on the differential case housing (19)

.

AR35.30-B-4300-04SP

 .Ring gear in the differential box

*BA35.30-B-1001-03SP

22

Install the retaining ring (23) on the splines of the planetary gear (22)

 The retaining ring (23) must seat against the stop of the planetary gear (22).

 The lip of the retaining ring (23) must be facing upwards.

23

Install the spring (24) on the lip of the retaining ring (23) and on the splines of the planetary gear (22)

 The small diameter (24) facing to the retaining ring (23).

 Check the spring travel (24) and ensure that it does not present malfunctioning (no gripping, overlapping of the spring coils, if there is good contact between the spring coils and the retaining ring (23)).

24

Install the two sets of driven clutch discs (25) on the spider (26)

 The “slit” in each retaining ring (23) must be properly aligned on the bigger tooth of the spider set (26).

25

Install the spider (26) and the set of clutch discs (25) over the spring (24)

26

Install the spring (24) over the clutch disc (25), the retaining ring (23) and the other planetary gear (22) over the spider set (26) and clutch disc (25)

27

Compress the set using the containment bolt, the washers and the wing nut

 Compress until the splines of the planetary gear (22) is totally engaged with the spines of the driven clutch discs (25).

 Use a hydraulic press for helping.

28

Place the ring gear (21) and the differential case housing (19) on a work bench

 The end of the tapered roller bearing (18) of the housing facing downwards and the inner section of the housing facing upwards.

 There should be nothing inside the differential case housing (19).

29

Install the self-locking differential in the cover of the differential case housing (27)

 There should be nothing inside the differential case housing (19).

30

Install the cover of the differential case housing (27) over the self-locking differential

 There should be nothing inside the differential case housing (19).

 The punch marks must be aligned.

 .Cover bolt of the differential box

*BA35.30-B-1002-03SP

31

Remove the wing nut, the washers and the containment bolt

32

Install the tapered roller bearings (29, 18) on the differential case

.

AR35.30-B-4300-01SP

.

AR35.30-B-4300-05SP

.

AR35.30-B-4301-03SP

33

Check the backlash of the ring gear (21) and pinion (13)

.

AR35.30-B-0475-02SP

34

Install the differential carrier (8) in the axle housing

.

AR35.30-B-0432SP

To be sure of the correct assembling of the components:



Perform the functioning tests

35

Refuel the axle with oil



.

AP35.00-B-3501SP

 .Oil filling plug

*BA35.10-B-1001-03D

Differential ring ear and pinion check values

Number

Designation

Rear axle 772.117 in Vehicles 979.272/277

BE35.31-B-1001-03SP

Clearance between ring gear/pinion

Values for new set

mm

0,13...0,25

Values for used set

mm

0,20...0,46

 Rear axle.

Number

Designation

Rear axle 772.117

BA35.10-B-1001-03D

Oil filling plug

Nm

47

 Central actuation with differential

Number

Designation

Rear axle 772.117 in Vehicles 979.272/277

BA35.30-B-1001-03SP

Ring gear in the differential box

M12X1.75

Nm

244

 Central actuation with differential

Number

Designation

Rear axle 772.117 in Vehicles 979.272/277

BA35.30-B-1002-03SP

Cover bolt of the differential box

M12X1.75

Nm

122