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 TABLE OF cONTENTS
TABLE OF cONTENTS

Page
6.0. REASSEMBLE (CONT)
Subject
3.0. DISASSEMBLE...*CARRIER FROM AXLE HOUSINGG..
* * * * ° * * * ° ' * ' . 6.14. INSTALL AND ADJUST THE THRUST SCREW
6.15. INSTALL DIFFERENTIALCARRIER INTO AXLE HOUSING
... . 72

3.1. REMOVE DIFFERENTIAL 11 (WITHOUT DIFFERENTIAL LOCK).... 73

ASsSEMBLY
.

3.2. REMOVE
DIFFERENTIALLOCK CARRIER. 12 7.0. DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK. 75
DIFFERENTIAL FROM THE
3.3. REMOVE THE 7.1. INSTALL DIFFERENTIAL SHIFT ASSEMBLY 76
AND
3.4. DISASSEMBLE THE DIFFERENTIAL 15
RING GEAR ASSEMBLY *** 7.2. INSTALL CARRIERINTO AXLE HOUSING
PINION AND BEARING CAGE (WITH DIFFERENTIAL LOCK) ......... . 30
3.5. REMOVE THE DRIVE * * * * * * * * * * * * * * * *
18
7.3. CHECK THE DIFFERENTIAL LoCK (IF EQUIPPED). 82
FROM CARRIER
PINION AND BEARING CAGE 20
3.6. DISASSEMBLE THE DRIVE 8.0. ADJUSTMENTS....... 33
4.0. CLEAN AND INSPECT... 25 8.1. ADJUST BACKLASH OF THE RING GEAR 83
25 8.2. DRIVE PINION BEARINGS - PRELOAD . 33
4.1. CLEAN .
25 8.3. DRIVE PINION DEPTH IN CARRIER 34
4.2. INSPECT
8.4. HYPOID GEAR ET TOOTH CONTACT PATTERNS
5.0. GENERAL PROCEDURESS 28 (HAND ROLLED)
5.1. REPAIR OR REPLACE PARTS 28 ...
..

:*:
29
8.5. ADJUST PRELOAD OF DIFFERENTIAL BEARINGS.
5.2. REPAIR AXLE BY WELDING.... 8.6. MAIN DIFFERENTIAL GEARS ROTATING RESISTANCE..
5.3. INSTALL NEW DRI-LOC FASTENERS 31
8.7. RING GEAR RUNOUT ......
-

35
5.4. INSTALL OLD DRI-LOC FASTENERS.... 31
5.5. CHECK TORQUE VALUES OF D -LOC FASTENERSS
8.8. SENSOR SWITCH INSTALLATION 85
8.9. SPIGOT BEARING PEENING ON THE DRIVE PINION... 5
NOT REQUIRING REMOVAL. 32
8.10. THRUST SCREW OR THRUST BLOCK - CLEARANCE....... 85
5.6. REMoVE DRI-LOC FASTENERS......
5.7. APPLICATION OF ADHESIVE IN BEARING BORES. 33 9.0 TORQUE CHART B6
5.8. APPLICATION OF SILICONE GASKET MATERIAL 34 9.1. PINION NUT BEARING PRELOAD TORQUE CHART. 36
5.9. INSTALL TIGHT FT YOKES . .

* ***** 35 9.2. TORQUE CHART.... . 87

5.10. GEAR SET INFORMATION (DRIVE PINION AND 10.0 SPECIAL TOOLS... 90
RING GEAR MARKS) . 36
10.1. THREE PIECE DIFFERENTIAL YOKEINSTALLATION TOOL..... 90
6.0. REASSEMBLE.... 38
6.1. DRIVE PINION, BEARINGS AND BEARING CAGE..... 38
6.2. INSTALL ONE-PIECE SPIGOT BEARING ASSEMBLIES 38
6.3. INSTALL TWO-PIECE SPIGOT BEARING ASSEMBLIES 41
6.4. ADJUST PRELOAD OF PINION BEARINGS.... . 44
6.5. ADJUST THICKNESS OF SHIM PACK FOR THE PINION CAGE
(DEPTH OF PINION) ... . * . 50
6.6. INSTALL THE DRIVE PINION, BEARING CAGE AND
SHIM PACK INTO
THE CARRIER . 53
6.7. ASSEMBLE THE MAIN DIFFERENTIAL AND
RING GEAR ASSEMBLY *** 55
6.8. ROTATING RESISTANCE CHECK OF
DIFFERENTIAL GEARS. 59
6.9.INSTALL THE DIFFERENTIAL... 60
6.10. ADJUST PRELOAD OF DIFFERENTIAL BEARINGS.
.

6.11. CHECK 62
RUNOUT OF RING GEAR.......
6.12. ADJUST BACKLASH 64
OF THE RING GEAR....
6.13. CHECK TOOTH CONTACT 65
PATTERNS OF THE GEAR SET..... 67
Page 2
CTS-5080T CTS-5080OT Page 3
 DESCRIPTION DESCRIPTION

1.2. SINGLE REDUCTION CARRIERS WITH DRIVER cONTROLLED MAIN

1. TAPERED ROLLER BEARING DIFFERENTIAL LOCK
2. CARRIER
Rockwell single reduction carriers with Differential Lock (Figure 1.02) have the same type of
3. STRAIGHT ROLLER BEARING
carriers.
4. TAPERED ROLLER BEARING
gears and bearings as the standard type
is mounted on the
5. BEVEL DIFFERENTIAL GEARS The differential lock is operated by an air-actuated shift assembly that
the splines of the
6. HOUSING carrier. When the differential lock is activated, the shift collar is moved along
with splines
7. TAPERED ROLLER BEARING axle shaft toward the differential case. When the splines on the collar are engaged
8. HYPOID DRIVE PINION AND on the differential case, the axle shafts and
differential assembly are locked together and there
in the unlocked
RING GEAR is no differential action between the wheels. When the carrier is operated
wheels all the time.
position, there is normal differential action between the

1. TAPERED ROLLER BEARING

2. SHIFT ASSEMBLY
3. SHIFT cOLLAR
4. AXLE SHAFT
5. SPLINES 13
6. TAPERED ROLLER BEARING
7. DIFFERENTIAL CASE 12
8. BEVEL DIFFERENTIAL GEARS
9. HOUSING
Figure 1.01 10. TAPERED ROLLER BEARING
11. STRAIGHT ROLLER BEARING
1.0. DESCRIPTION
When the carrier operates, there is normal
differential action between the wheels all the
12. HYPOID DRIVE PINION
AND RING GEAR
1.1. STANDARD SINGLE REDUCTION time. 13. CARRIER
CARRIERS WITHOUT
DIFFERENTIAL LOCK
Rockwell single reduction standard carriers
(Figure 1.01) are used in most Rockwell
single axles, rear or tandem axles and front
drive steering axles.

The single reduction carrier models are front

mounted into the axle housing. These
carriers have a hypoid drive pinion and 10
ring
gear set and bevel gears in the differential
assembly.
A straight roller bearing (spigot) is mounted
on the head of the drive pinion. All other
bearings in the carrier are tapered roller
bearings. Flgure 1.02

Page 4
CTS-5080T CTS-508OT Page 5
 VEHICLE TOWING INSTRUCTIONSs
VEHICLE TowING INSTRUCTIONS

2.0. VEHICLE TOWING 4. Remove both axde shafts of drive axles

that will remain on the ground while the
INSTRUCTIONS
vehicle is being towed.
2.1. BEFORE TOWING NOTE: If the axle(s) are equipped with
10
When towing or "piggybacking" a vehicle main differential lock, the left-hand front
with the wheels of one or both drive axles on axle shaft and rlght-hand rear axle shaft
the ground, it is possible to damage the of tandem axles and the right-hand axle
axles or cause additional damage if the shaft of single axles have two sets of
wrong procedure is used before towing splines. One set of splines ls engaged
begins. Rockwell recommends that you use with the slde gear and one set is engageed
the following procedure. with the shift collar. It may be necessary
to rotate the shaft when pulling it through
If the drive axle(s) is equipped with a main the shift collar (Figure 2.02) (single or
differential lock, shift the differential to the rear of tandem axle shown).
unlocked (disengaged) position. The
differential lock light in the cab of the vehicle 5. Install a cover over the openings of both
will go out. hubs to retain the lubricant and keep dirt
1. ACTUATOR ASSEMBLY AND SHIFT FORK
from entering the hub.
2. AXLE SHAFT
NOTE: If the air supply to the diferential
2.3. INSTALL AXLE SHAFTS 3. INTERFERENCE BETWEEN SHIFT
lock is damaged, the differential will COLLAR AND HOUSING
unlock (disengage) when air pressure is 1. Remove the covers from the hubs. 4. SHIFT cOLLAR IN UNLOCKED POSITION
lost.
2. If the drive axle(s) is equipped with a 5. OUTER SPLINES AXE SHAFT
main differential lock, shift the differential TO SHIFT cOLLAR
2.2. REMOVE AXLE SHAFTS
to the unlocked (disengaged) position.
Install the axle shafts with two sets of
6. SHIFT cOLAR AND DIFFERENTAL
CASE SPLNES
1. Identity each axle shaft so that they can
be installed in the same location after splines and new gaskets in the correct 7. INNER SPUNES AXE SHAFT TO SIDE
locations as follows: GEAR
repair is completed.
8. SIDE GEAR
2. Remove capscrews* and washers or A. Push the right axle shaft and gasket
9. DIFFERENTIAL (PLAIN) CASE HALF
washers from flanges of
stud nuts and into the hub and housing until the 10. SHIFT cOLLAR IN LOCKED POSITION
both axle shafts. shaft stops against the shift collar
NOTE: A 1-1/2 inch diameter brass B. Push down and in on the axle shaft Flgure 2.002
hammer can be used as a drift. flange and rotate the shaft until the
splines of the shaft and collar are
3. Hit the end of the drift with a large engaged.
hammer (five to six pounds) and the axle
shaft and tapered dowels will loosen C. Push the axle shaft further into the
(Figure 2.01). housing until the shaft stops against
the differential side gear.
CAUTION - Do not use a chisel o
D. Push down on the axle shaft flange
wedge to loosen the axle shafts and and rotate the shaft until the splines of
dowels. The chisel or wedge can the shaft and side gear are engaged.
damage the hub, axle shafts and, if 1. BRASS HAMMER
used, oil seals. 2. DRIVING LUG E. Push the axle shaft completely into
the housing until the flange and
Figure 2.01 gasket are flush against the hub.
Some Rockweill Cariers do not have the parts descrbed.
Page 6
CTS-508OT CTS-508OT Page 7
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 DISASSEMBLE DISASSEMBLE

To align the splines, use the following CAUTION When using a pry bar, be
procedure careful not to damage the carrier or
housing flange. Damage to these
A. Rotate the drive pinion or right-hand
surfaces will cause oil leaks.
wheel to align the splines of the shift
collar and case half while you turn in
the manual engaging capscrew.
13. Remove and discard the carrier-to-
B. When the normal amount of spring housing gasket.
resistance is again felt on the
14.Lift the differential carrier by the input
capscrew, the splines are engaged.
Continue to turn in the
yoke or flange and put the assembly in a
manual repair stand (Figure 3.03). Use a lifting
engaging capscrew until the head is tool for this procedure. Do not lift by
approximately 1/4 inch from the hand. The repair stand is available
cylinder cover.
through PD.c. Refer to SPECIAL TOOLS,
Place a hydraulic roller jack under the page 90.
differential carrier to support the
assembly (Figure 3.02). 1. DIFFERENTIAL CARRIER

8. Remove all but the top two carrier-to- 2 REPAIR STAND

housing capscrews or stud nuts and Figure 3.03
washers 3.2. REMOVE DIFFERENTIAL LOCK
9. Loosen the top two carrier-to-housing
fasteners and leave attached to the
ASSEMBLY

assembly. The fasteners will hold the 1. To remove the differential lock sliding
carrier in the housing. 1. WOOD BLOCK shift collar, tap out the two retainer roll
2. HYDRAULIC JACK pins until they are level with the inner face
10. Loosen the differential carrier in the axle of the shift fork (Figure 3.04). Release the
housing. Use a leather mallet to hit the Flgure 3.02 differential lock if it is manually engaged.
mounting flange of carrier at several
points
NOTE: Some carrier models have
threaded puller screw holes in the
mounting flange. Puller screws can be 1. SHIFT FORK
used to loosen and pull the carrier from
2. ROLL PIN
the axle housing. If puller screws are
3. SHIFT cOLLAR
used, clean the threaded holes before the
puller screws are installed. Figure 3.04

11.Afterthe carrier is loosened, remove the

top two fasteners.
12. Carefully remove the carrier from the axle
housing using the hydraulic roller jack.
Use a pry bar that has a round end to
help remove the carrier from the housing

Page 10 CTS-5080OT Page 11

CTS-5080T
 DISASSEMBLE DISASSEMBLE

2. If required, remove the differential lock 1. Loosen the jam nut* on the thrust
shift unit. screw*
A. Remove the sensor switch and lock 2. Remove the thrust screw* and jam nut*
nut. from the differential carrier (Figure 3.07).
B. Remove the four capscrews and
washers that hold the cylinder cover.
Remove the cover and copper gasket
(Figure 3.05).
C. Remove the shift unit-cylinder and
piston. Remove the 0-ring from the
piston.
D. Remove the shift shaft from the shift Figure 3.07
1. COVER (COPPER GASKET
fork. The shaft may be loctited to the UNDER COVER)
fork; use the heating procedure to
break down loctite. Refer to REMOVE 2 CAPSCREW AND WASHER 1. THRUST BLOCK
DRI-LOC FASTENERS, page 32. Figure 3.05
2. THRUST SCREW
AND JAM NUT
E. Remove the shift shaft spring and flat
washer.
NOTE: Some Rockwell carrler models
NOTE: Some models use silastic seal have a thrust block". The thrust block will
instead of the flat washer in Step E. fall away from the ring gear inside the
carrier when you remove the thrust screw
F Remove the shift fork.
(Figure 3.08).
NOTE: A roll pin is installed in the shift
3. Rotate the differential carrier in the repair
shaft and is used as a stop for the shift
stand until the ring gear is at the top of
shaft spring. It is nota necessary to remove
this roll the assembly.
pin during normal disassembly.
3.3. REMOVE THE DIFFERENTIAL Figure 3.08
FROM THE CARRIER
NOTE: Before you start work on the
differential carrier, inspect thee hypoid
gear set for damage. If the inspection
shows no damage, the same gear set can
be used again. Measure the backlash of 4. Mark one carrier leg and bearing cap for
the gear set and make a note of the the purpose of correctly matching the
parts when you assemble the carrier. A
dimension (Figure 3.06). Refer to ADJUST
BACKLASH OF RING GEAR, page 65.
center punch and hammer can be used
to mark the parts (Figure 3.09).
1. BEARING CAP
2. CARRIER LEG
3. MATCH MARKS

Figure 3.06 Flgure 3.09

Some Rockwell Carriers do not have the parts described.

Page 12 CTS-5080T Page 13
CTS-5080OT
 DISASSEMBLE DISASSEMBLE

7. Remove the bearing

caps and bearing
5. Remove the cotter keys*, pins* or lock adjusting rings from the carrier (Figure
plates* that hold the two bearing9 3.112).
adjusting rings in position. Use a small
drift and hammer to remove pins. Each
lock plate is held in position by tw
capscrews (Figure 3.10) ADJUSTING RING
2. BEARING CAP

Figure 3.12

8. Safely lift the main differential and ring

gear assembly from the carrier. Put the
assembly on a work bench (Figure 3.13).
9. Remove the thrust block* from inside the
carrier.
REMOVING COTTER KEY
2. REMOVING LOCK PLATE

Figure 3.10 Figure 3.13

3.4. DISASSEMBLE THE DIFFERENTIAL

AND RING GEAR ASSEMBLY

1. If the matching marks on the case halves

6. Remove the capscrews and washers that of the differential assembly are not
hold the two bearing caps on the carrier. visible, mark each case half with a center
Each cap is held in position by two punch and hammer. The purpose of the
marks is to match the plain half and
capscrews and washers (Figure 3.11).
flange half correctly when you assemble
the carrier (Figure 3.14).

Figure 3.11 Figure 3.14

Some Rockwll Carriers do nothavethe pats described Some Rockwell Carriers do not have the parts described.
Page 14 CTS-5080T Page 15
CTS-508OT
 DISASSEMBLE DISASSEMBLE

2. Remove the lock wire*, capscrews* and

washers* or bolts*, nuts* and washers
that hold the case halves together.

WARNING- Wear safe eye 7. Separate the case half and ring gear
protection. Do not hit steel parts with using a press. Support the assembly
a steel hammer. Parts can break and under the ring gear with metal or wood
cause injury. blocks and press the case half through
the gear (Figure 3.17).

3. Separate the case halves. If necessary,

use a brass, plastic or leather mallet to 1. PRESs 3. SUPPORTS
loosen the parts.
2 PLATE 4. CASE HALF
4. Remove the differential spider (cross),
four pinion gears, two side gears and six Figure 3.17
thrust washers from inside the case
halves (Figure 3.15).
1. THRUST WASHER
5. If the ring gear needs to be replaced, 2. SIDE GEAR PULLER
remove the bolts*, nuts* and washersS
that hold the gear to the flange case half. 3. SPIDER PINION AND THRUST WASHER

6. If rivets* hold the ring gear to the flange Figure 3.15

case haif, remove the rivefs as follows:
8. If the differential bearings need to be PRESS
A. Carefully center punch each rivet replaced, remove the bearing cones fromn
head in the center, on the ring gear the case halves. Use a bearing puller or
side of the assembly. press (Figure 3.18).
B. Drill each rivet head onthe ring gear
side of the assembly to a depth equal
to the thickness of one rivet head.
Use a drill bit that is 1/32 of an inch
smaller than the body diameter of the
rivets (Figure 3.16).
C. Press the rivets through holes in the cORRECT WAONG Figure 3.18
ring gear and flange case halif. Press Figure 3.16
from the drilled rivet head.

CAUTION Do not remove the rivets

or rivet heads with a chisel and ham-
mer. The chisel can damage the
flange case half (Figure 3.16).

*SomeRockwell Carriersdonothavethe partsdescribed

Page 16 CTS-5080T Page 17
CTS-5080T
 DISASSEMBLE DISASSEMBLE

5. Remove the capscrews and washers that

3.5. REMoVE THE DRIVE PINION
AND hold the bearing cage in the carrier
BEARING CAGE FROM CARRIER
(Figure 3.21).
1. Fasten a yoke or flange bar to the input
yoke or flange. The bar will hold the drive WARNING Wear safe eye
pinion in position when the nut is
removed (Figure 3.19). protection. Do not hit steel parts with
a steel hammer. Parts can break and
2. Remove the nut and washer* from the cause injury.
drive pinion. 1. BEARING CAGE 2. CARRIER
3. Remove the yoke or flange bar. Figure 3.21
6. Remove the cover* and seal assembly
and gasket* from the bearing cage
(Figure 3.22). If the cover* is tight on the
bearing cage, use a brass drift and
hammer for removal.
7. If the pinion seal is damaged, remove the
seal from the cover*. Use a press and
sleeve or seal driver. If a press is not
1. FLANGE BAR available, use a screwdriver or small pry
2. YOKE BAR bar for removal. Discard the pinion seal.
Figure 3.19
NOTE: If the carrier does not have a cover BEARING CAGE
and seal assembly, the pinion seal will be
2 GASKET
mounted In the outer bore of the bearing
4. Remove the yoke or flange from the drive cage. Remove the seal after the drive
3. coVER AND SEAL ASSEMBLY
If the yoke or fange is tight on the YOKE PULLER Figure 3.22
pinion.
pinion, use a puller for removal (Figure
pinion is removed from the bearing cage.

3.20). The yoke puller is available

through PD.C. Refer to SPECIAL TOOLS,
8. Remove the drive pinion, bearing cage
and shims from the carrier. If the bearing
page 90. cage is tight in the carrier, use the
following procedures to loosen the cage
CAUTION Do not use a
hammer or (Figure 3.23).
mallet to loosen and remove the yoke
or flange. A hammer or mallet can
damage the parts and cause runout WARNING Wear safe eye
protection. Do not hit steel parts with
or alignment problems.
a steel hammer. Parts can break and
cause Injury.
FLANGE
PULLER A. Hit the bearing cage at several points 1. DRIVE PINION AND BEARING CAGE
around the flange area with a leather, 2. SHIMSs
plastic or rubber mallet.
Flgure 3.23
Figure 3.20

Some Rockwell Camers do not have the parts described.

Some Rockwll Carriera do not havo the parts described
Page 18
CTS-5080T CTS-5080T Page 19
 DISASSEMBLE
DISASSEMBLE
B. Some bearing cages have threaded
puller screw holes* in the
2. Support the bearing cage under the
mounting flange area with metal or wood blocks
flange. Puller screws canfitted
loosen and
be used to
(Figure 3.26).
pull tightly
a cage
from the carrier. If puller screws are 3. Press the pinion shaft through the
used, clean the threaded holes before bearing cage (Figure 3.26).
the puller screws are installed (Figure NOTE: The inner bearing cone and
3.24) bearing spacer or spacers will remain on
the pinion shaft.
CAUTION Do not pry bar to
use a

remove the bearing cage from the

carrier. A pry bar can damage the WARNING- Wear safe eye
bearing cage, shims and carrier. protection. Do not hit steel parts with
1. BEARING CAGE a steel hammer. Parts can break and
2. PULLER SCREW cause injury. 1. PINION SHAFT
9. If the shims are in good condition, keep 4. SUPPORT
2. OIL SEAL
the shims together for use later when the Figure 3.24 4. Ifa press is not available, use a leather, 3. BEARING CAGE5. SPIGOT BEARING
carrier is assembled. plastic or rubber mallet to drive the
10. If shims are to be discarded because of pinion shaft through the bearing cage. Figure 3.26
damage, first measure the total thickness 5. IH the pinion oil seal is mounted directly in
ofthe pack. Make a note of the the outer bore of the bearing cage,
dimension. The dimension will be
to calculate the depth of the drive remove the seal at this time. Be careful
needed
pinion in the carrier when the gear set is
that you do not damage the mounting
surfaces of the bearing cage (Figure
installed.
3.27).
3.6. DISASSEMBLE THE DRIVE PINION If the seal is a one-piece design (without
AND BEARING CAGE mounting flange), discard the seal.
1. Put the drive pinion and bearing cage in If the oil seal is a triple-lip design (with
a press. The pinion shaft must be toward flange), inspect the seal for damage. If
the top of the assembly (Figure 3.25). the surfacessmooth
of the seal and the yoke or Figure 3.27
fiange are and not worn or
damaged, you can use the seal again
when you assemble the carrier.

CAUTION Be careful when using a

1. OIL SEAL 5. SNAP RING screwdriver or pry bar to remove the
2. OUTER BEARING
CUP AND CONE
6. BEARING SPACER seal. Do not damage the wall of bore.
3. INNER BEARINGG
7. FLANGE OR YOKE Damage to the bore can cause oil
SPACER leaks.
CUP AND CONE
8. PINION SHAFT
4 SPIGOT BEARING
Figure 3.25

Some Rockwell Carriers do not have the parts described.

Page 20 CTS-508OT CTS-5080T Page 21
 DISASSEMBLE DISASSEMBLE

8. If the spigot bearing needs tobe

replaced, put the drive pinion in a vise.
Install a soft metal cover over each vise
jaw to protect the drive pinion.
BEARING DRIVER 9. Remove the snap ring* from the end of
6. If the pinion bearings need to be
replaced, remove the inner and outer drive pinion with snap ring pliers that
bearing cups from the inside of cage. expand (igure 3.30).
Use a press and sleeve, bearing puller or BEARING
a small drift and hammer. The type of tool PULLER
used depends on the design of the
bearing cage (Figure 3.28).
When a press is used, support the 1. SPIGOT BEARING
under the flange area with 2. SNAP RING
bearing cage
metal or wood blocks.
Figure 3.30

Figure 3.28

NOTE: Some spigot bearings are fastenedd

to the pinion shaft with a special peening
7. If the pinion bearings need to be tool (Figure 3.31).
replaced, remove the inner bearing cone
from the pinion shaft with a press or
bearing puller. The puller MUST fit under
the inner race of the cone to remove the
cone correctly without damage (Figure
3.29).

1. PINION SHAFT
Flgure 3.31

2. BEARING PULLER
3. SUPPORTS
4. INNER BEARING CONE
Figure 3.29

Some Rockwell Carlers do not havo the parts doscrbed.

Page 22 CTS-5080T CTS-5080T Page 23
 DISASSEMBLE CLEAN AND INSPECT

4.0. CLEAN AND INSPECT 4.1.3. Axle Assemblies

1. A complete axle assembly can be
4.1. CLEAN steam cleaned on the outside to remove
dirt.
4.1.1. Ground and Polished Partss
10. Remove the spigot bearing from the 2. Before the axle is steam cleaned, close
pinion sha with a bearing puller (Figure 1. Use a cleaning solvent to clean ground or put a cover over all openings in the
32). or polished parts or surfaces. Kerosene axle assembly. Examples of openings are
or diesel fuel oil can be used for this breathers or vents in air chambers.
purpose. DO NOT USE GASOLINE.
4.1.4. Dry Parts That Have Been Cleaned
WARNING-Be careful when 1. Parts must be dried immediately after
1. BEARING PULLER
2. SPIGOT BEARING using cleaning solvents. Follow the cleaning and washing9.
solvent manufacturer's Instructions
2. Dry the parts using soft, clean, paper or
Figure 3.32 for safe use to prevent injury. cloth rags.
2. Use a tool with a flat blade if required to 3. Except for bearings, parts can be dried
remove gasket material from parts. BBe with compressed air.
careful not to damage the ground
REMOVE oUTER RACE surfaces. CAUTION Damage to bearings can
AND ROLLER ASSY. be caused if dried by rotating with
NOTE: Some spigot bearings are a FROM CARRIER compressed air.
CAUTION DO NOT clean ground or
two-piece assembly. Remove the inner
polished parts in a hot solution tank,
race from the pinion shaft with a bearing
water, steam or alkaline solutions.
puller. Remove the outer race/roller
assembly from carrier with a drift or a
4.1.5. Prevent Corrosion and Rust on
Cleaned Parts
press (Figure 3.33). 4.1.2. Rough Parts 1. Apply axde lubricant to cleaned and dried
REMOVE INNER RACE 1. Clean rough parts the same as cleaning parts that are not damaged and are to be
FROM PINION assembled.
ground and polished parts.
Figure 3.33 2. Rough parts can be cleaned in hot 2. To store parts, apply a special material
solution tanks with a weak alkaline that prevents corrosion and rust to all
solution. surfaces. Wrap them in a special paper
that prevents corrosion and rust.
3. Parts must remain in hot solution tanks
until completely cleaned. 4.2. INSPECT
It is very important to inspect all parts
WARNING- Be careful when
before the
using hot solution tanks and alkaline carefully and completely
camier is assembled. Check all parts for
axle or
solutions. Follow the alkaline
manufacturer's Instructlons for safe wear and replace damaged parts.
use to prevent Injury, Replacement of damaged or worn parts now
will prevent failure of the assembly later.
4. Parts must be washed with water until the
solution is removed.

Page 24
CTS-508OT CTS-5080T Page 25
 CLEAN AND INSPECT CLEAN AND INSPECT

1. Inspect Tapered Roller Bearings ETCHING & PITTING

Inspect the cup, cone, rollers and cage

of all tapered roller bearings in the
assembly. If any of the followingg F. Damage on rollers and on surfaces of
exist, the bearing MUST be the cup and cone inner race that
conditions
replaceed. touch the rollers (Figure 4.04).

A. The center of large diameter end of

rollers worn level with or below the
outer surface (Figure 4.01). Figure 4.04
B. The radius at large diameter end of 1. WORN RADIUS
rollers worn to a sharp edge (Figure
4.01). 2. WORN SURFACE SPALLING &FLAKING
Figure 4.01
C. A visible roller groove in the cup or
cone inner race surfaces. The groove
can be seen at the small or large
diameter end of both parts (Figure G. Damage on the cup and cone inner
4.02). race surfaces that touch the rollers
D. Deep cracks or breaks in the cup, (Figure 4.05).
cone inner race or roller surfaces 2
2. Inspect Hypoid Drive Pinion and Ring
(Figure 4.02). Gear Sets.
A. Inspect hypoid pinions and gears for
wear or damage. Gears that are worn
or damaged MUST be replaced.

CAUTION- Hypoid drive pinions

ring gears are machined in matched
and
Figure 4.05
sets. When a drive pinion or ring gear
of a hypoid set needs to be replaced,
both drive gear and pinion must be
1. CRACK replaced at the sanme time.
2. WEAR GROOVE
Figure 4.02

E. Bright wear marks on the outer

Surface of the roller cage (Figure
4.03).

WEAR MARKS
Flgure 4.03

Page 26
CTS-5080T CTS-508OT Page 27
 PROCEDURES GENERAL PROCEDURES
CLEAN AND INSPECT, GENERAL

3. Inspect the Main Differential Assembly. 5. Remove nicks, mars and burrs from
parts having machined or ground
Inspect the following parts for wear or
surfaces. Use a fine file, India stone,
stress. Parts that are damaged MUST be
emery cloth or crocus cloth for this
replaced (Figure 4.06). purpose.
A. Inside surfaces of both case halves.
6. Clean and repair threads of fasteners and
B. Both surfaces of all thrust washers. holes. Use a die or tap of the correct size
or a fine file for this purpose.
C. The four trunnion ends of the spider
(cross). X CAUTION Threads must be without
D. Teeth and splines of both differential DIFFERENTIAL CASE HALVES damage and clean so that accurate
side gears. adjustments and correct torque valuees
INSPECT can be aplied to fasteners and parts.
E. Teeth and bore of all differential
pinions.

CAUTION - Always replace thrust 7. Tighten all fasteners to the correct torque
values (Figure 5.02). Refer to the
washers, differential side gears and
TORQUE CHART, page 87.
pinion gears in sets. A higher stress
on parts and early failure of the as-
sembly will occur if a new part is
INSPECT CAUTION DO NOT repair rear axle
housings by bending or straightening.
used with parts that are old or worn.

ALWAYS USE TORQUE WRENCHES

4. Inspect axle shafts for wear and cracks at
the flange, shaft and splines. Replace
axle shaft if required.
Ahousings
WARNING Repair of axle
by bending or straightening Figure 5.02
INSPECT will cause poor or unsafe operation of
the axle and early failure.
DIFFERENTIAL GEAR NEST ASSEMBLY
5.0. GENERAL PROCEDURESs
1. INSPECT INSIDE SURFACE

5.1. REPAIR OR REPLACE PARTS 2. SIDE GEAR AND THRUST WASHER 5.2. REPAIR AXLE BY WELDING
3. SPIDER CROSS
Replace worn or damaged parts of an axle 1. Repairing drive axle housing assemblies
assembly. The following are some examples 4 PINION AND THRUST WASHER by welding is permitted ONLY in the
to check for, repair or replace. Figure 4.06 following areas:
1. Replace any fastener if corners of the A. Cover welds.
head are worn.
B. Snorkel welds.
2. Replace washers if damaged.
C. Housing seam welds between the
3. Replace gaskets, oil seals or grease suspension attaching brackets.
seals at the time of axle or carrier repair.
4. Clean parts and apply new silicone
gasket material where required when
axle or carrier is assembled (Figure
5.01).
Figure 5.01

Page 28
CTS-5080T CTS-5080OT Page 29
 GENERAL PROCEDURES GENERAL PROCEDURES

heat the
F Before you start welding, 4. Install the differential carrier and axle
CAUTION- Welding can be used be repaired to
damaged area to shafts.
approximately 300° (149° C).
when the crack or damaged area is F
5. Fill the axle assembly with the correct
within the old weld material. Replace weld material
the axle housing if the crack extendsS G. Use a 70,000 psi tensile amount of lubricant. Refer to GROUP 10
and - LUBRICATION.
into the metal next to the old weld. A and the correct voltage
diameter weld rod
amperage for the
housing that has damage in the seam that can INSTALL NEW DRI-Loc
weld or cover weld because of used. Examples of weld rods 5.3.
load conditions can be repaired. A
over be used are E-7018 or ER-705-3. FASTENERS

repaired housing must be used in 1. Clean the oil and dirt from threaded
CAUTION- If the E-7018 weld rod is
correct applications. holes. There is no special cleaning
used, the rod must be kept dry. Elec required.
trodes that are not stored in the cor
rect sealed containers must be
2. Assemble parts using new Dri-Loc
heated at 700°F (371°C) for one hour fasteners.
WARNING- Using wrong
welding procedures or welding at before welding. Wet electrodes must
locations other than the three areas be dried at 180°F (82°C) for one to CAUTION Do not-

apply adhesivees
or sealants on new Dri-Loc fasteners
permitted will make the heat-treated two hours and then heated at 700°F
or in the threaded holes. If other
component weak. A weak component (371°C) for one hour before welding. adhesives or sealants are used, the
will cause poor or unsafe operation new DriLoc adhesive will not func-
of the axle and early failure. The
tion correctly.
following procedure must beused. 3. Fill in the Weld Gap as Follows:

CAUTION - Do not connect the

2. Welding Procedure. 3. Tighten the Dri-Loc fasteners to the
ground cable at any point on the axle
A. Drain the lubricant from the axle
assembly that will put a bearing be- required torque value for that size
assembly. fastener. Refer to the TORQUE CHART,
tween the ground cable and weld
page 87.
B. Remove the axle shafts and area. If a bearing is between the
differential carrier from the axle ground cable and weld, the bearing NOTE: There is no drying time required
housing. for Dri-Loc fasteners.
will be damaged because of electric-
ityarcing.Agood location to connect
AWARNING- Be careful when the ground cable is the spring mount 5.4. INSTALL OLD DRI-LoC
using a cleaning solvent. Follow the ing pad of the housing. FASTENERS
solvent manufacturer's instructions
1. Clean the oil and dirt from threaded
for safe use to prevent injury. A. The snorkel weld MUST be a .375
holes. There is no special cleaning
inch (9.5 mm) fillet. required and it is not necessary to
C. Clean the damaged area inside and remove the old Dri-Loc adhesive from
the Cleaning solvent
outside housing.
can be used.
B. The opening in cover welds MUST be threads.
filled level with the old weld. 2. Apply four or five drops of Loctite 277 to
D. Grind the damaged weld to the base C. The threaded holes ONLY. Make sure the
opening in seam welds MUST be
metal ground out to 70% of the wal adhesive is on the threads (Figure 5.03).
E. Warm the complete axle housing to a thickness. The wall thickness can be 4 TO 5
temperature of 70°F to 80°F (21°C to measured at the carrier opening ot CAUTION D o not apply adhesive to DROPS
the fastener threads. Air pressure in ON
27 C) or higher. housing. THREADS
D. Clean the new the hole will push the adheslve out as
weld area. Flgure 5.003
remove all the
rough weld
Carefully
material.
the fastener lsinstalled.

Page 30
CTS-5080T CTS-5080T Page 31
 GENERAL PROCEDURES
GENERAL PROCEDURES

5.7. APPLICATION OF ADHESIVE IN

3. Tighten the fasteners to the required BEARING BORES
torquevalue for that size fastener. Refer
to the TORQUE CHART, page 87, for the Use Loctite Sleeve N' Bearing Mount No.
correct torque value (Figure 5.04). 609 (Green).
NOTE: There is no drying time required 1. Clean the oil and dirt from outer
for Loctite 277. diameters of bearing cups and bearing
bores in the carrier and bearing caps.
5.5. CHECK TORQUE VALUES OF There is no special cleaning required.
ALWAYS USE TORQUE WRENCHES
DRI-LOC FASTENERS NOT
2. Apply axle lubricant to the bearing cones
REQUIRING REMOVAL Figure 5.04 and the inner diameters of the bearing
cups of the main differential. DO NOT get
CAUTION - If Dri-Loc fasteners do
oil on the outer diameter of the bearingg
not require removal from compo DO NOT permit oil to drip on the
nents, check the fasteners for correct
cup and
bearing bores.
torquevalue as follows: 3. Apply a single continuous bead of the
adhesive to the bearing bores in the
1. Apply the MINIMUM amount oftorque carrier and bearing caps. Apply
required for that size fastener. Refer to the
the TORQUE CHART, page 87. The adhesive 360° around the smooth,
fastener MUST NOT rotate (Figure 5.04). ground surfaces ONLY. DO NOT put
adhesive on threaded areas (Figure
2. If the fastener rotates any amount,
remove the fastener from the component 5.05).
NOTE: The Loctite No. 609 adhesives will
and apply adhesive to the threaded
Follow the procedure for INSTALL OLD
hole. become hard (dry) in approximately two
DAI-LOC FASTENERS, page 31. hours. The following two steps of the
1. ADHESVE
5.6. REMOVE DRI-LoC FASTENERS.
procedure must be done In two hours 2 BEARING CAP
from the time the adhesive was applied. It
3. CARRIER LEG
If it is difficult to remove Dri-Loc fasteners two hours have passed since application,
from components, the strength of Dri-Loc clean the parts again and apply new Figure 5.05
or Loctite 277 can be decreased by heating. adhesive.
Use the following procedure:
4. Install the main differential assembly,
1. Heat the fastener for three to five bearing cups and bearing caps into the
seconds ONLY and try to loosen the carrier. Refer to ASSEMBLE THE MAIN
fastener with a wrench. DO NOT use an DIFFERENTIAL AND RING GEAR
impact wrench to loosen the fastener or ASSEMBLY, page 55.
hit the fastener with a hammer.
5. Adjust preload of the differential
2. Repeat step 1 until the fastener can be bearings, backlash and tooth contact
removed. patterns of the gear set as required using
the normal procedures. Refer to ADJUST
CAUTION Do not exceed 350°F (+ PRELOAD OF DIFFERENTIAL
177 C) maximum. Heating must be
done slowly to prevent thermal
BEARINGS, page 62, and ADJUST
BACKLASH OF THE RING GEAR, page
stressesin the other components. 65, and CHECK TOOTH CONTACT
PATTERNS OF THE GEAR SET, page 67.

Page 32 CTS-5080T Page 33

CTS-5080T
 GENERAL PROCEDURES
GENERAL PROCEDURES

5.8. APPLICATION OF SILICONE 6. Wait 20 minutes before the assembly is

GASKET MATERIAL filled with lubricant.
NOTE: The following silicone gasket
products can be used on components. 5.9. INSTALL TIGHT FIT YOKES wBRICATE
SEAL
A three-piece installation tool is required to
Dow Corning Silicone Rubber
correctly install yokes with interference CHECK YOKE HUB
Sealant, No. 732 Black.
splines (Figure 5.08). The installation tool is
B. General Electric No. RTV-1473 available from PD.C. Refer to SPECIAL
Black. TOOLS, page 90.

WARNING- Small amounts of

acid vapor are present when applying
CAUTION- Do not install tight fit 1. INPUT SHAFT
(PINION)
yokes on shafts using a hammer or
silicone gasket material. For this mallet. A hammer or mallet will PILOT SHAFT
reason, be sure there is good ventila- damage the yoke andjor bearing9. 3 YOKE
tion in the work area. If the silicone 4 COLLAAR
gasket material gets in the eyes, flush
NUT
the eyes with water for 15 minutes. 1. Apply axle lubricant on the yoke seal.
Have the eyes checked by a doctor. Figure 5.08
2. Check all surtaces of the yoke hub for
damage. f necessary, polish the yoke
1. Remove all old gasket material from both hub with an India stone, emery cloth or
surfaces (Figure 5.06). crocus cloth.
2. Clean the 3. Install the pilot shaft on the input shaft of
where silicone gasket
surfaces the assembly (Figure 5.08).
material will be applied. Remove all oil,
grease, dirt and moisture. 4. Slide the yoke over the pilot shaft. Align
3. Dry both surfaces. the yoke splines with the shaft splines.

4. Apply a 1/8 inch diameter continuous 5. Put the collar on the pilot shaft and slide
bead of the silicone gasket material it against the yoke.
1. HOUSING
around one surface. Also apply gasket 6. Install the nut on the pilot shaft and
2. CARRIER
material around the edge of all fastener against the collar. Tighten the nut against
holes in that surface (Figure 5.07). Figure 5.06 collar until the yoke is completely in
position on the shaft. Sometimes a
CAUTION The amount of silicone 1/8 INCH
torque value of 200 ft-Ibs. on the nut is
must not
gasket material applied BEAD
required to install the yoke correctly.
exceed a 1/8 inch diameter bead.
Too much gasket material can block
OF SILICONE
CAUTION - Do not use the assembly

lubrication passagesS. yoke nut for Installation purposes.

Use the nut that is supplied with the
5. Assemble the components immediately three-plece pllot tool.
to permit the silicone gasket material to
compress evenly between the parts.
Tighten fasteners to the required torque
value for that size fastener. Refer to the
TORQUE CHART, page 87
Flgure 5.07

Page 35
Page 34 CTS-5080T CTS-5080T
 GENERAL PROCEDURES GENERAL PROCEDURES

3. Gear Set Match Number

7. Remove all parts of the pilot tool from the
shaft (pilot shaft, collar and nut). Rockwell drive pinions and ring gears are
8. Install the washer (f required) and yoke available only as matched sets. Both
gears of a set have a match number.
nut on the shaft. Tighten the nut to thee
required torque value. Refer to the A. Example of a gear set match number:
TORQUE CHART, page 87. M29.

5.10. GEAR SET INFORMATION (DRIVE NOTE: A gear set match number has anyY
PINION AND RING GEAR MARKS) combination of a number or letter and
number.
NOTE: Before a new gear set is installed PART
in the carrier, read the following NO~ B. Location on Drive Pinion: End of gear
information. Always check the gear set for head.
PART
correct marks to make sure the
gears are NO.
a matched set. The locations of the marks C. outer
Location Ring Gear: Front facee
on
diarmeter.
or

are shown in Figure 5.09.

4. Pinion Cone Variation Number
1. Part Number PART NO. OPTION
The pinion cone variation number is not
Figure 5.009
A. Examples of gear set part numbers: used when checking for a matched gear set.
Conventional ring gear, 36786. The number is used when you adjust the
Conventional drive pinion, 36787.
Generoid ring gear, 36786 K or depth of the pinion in the carrier. Refer to
36786 K2.
ADJUST THICKNESS OF SHIM PACK FOR
Generoid drive pinion, 36787 K or THE PINION CAGE, page 50.
36787 K2.
A. Examples of pinion cone variation
NOTE: The last digit in part numbers for numbers: PC+3, PC-5, +2,-1,
Generoid gears is a letter or letter and +.01 mm or -02 mm (Figure 5.10).
number. B. Locationon Gear Set: End of
pinion
B. Location on Drive Pinion: End at gear head or outer diameter of ring
threads. gear (Figure 5.10). Figure 5.10
C. Location on Ring Gear: Front face or
outer diameter.
2. Tooth Combination Number
A. Example of a tooth combination
number: 5-37.

NOTE: A 5-37 gear set has a 5-tooth

drive pinion and a 37-tooth ring gear.

B. Location on Drive Pinion: End at

threads.
C. Location on Ring Gear: Front face or
outer diameter.

Page 36 CTS-5080T CTS-5080OT Page 37

 REASSEMBLE
REASSEMBLE

A. Put the drive pinion in a press, gear

6.0. REASSEMBLE head (teeth) toward the top (Figure
PRESS

6.1. DRIVE PINION, BEARINGS AND 6.03)

BEARING CAGE B. Press the spigot bearing on the end
of drive pinion until the bearing is fat
1. Put the bearing cage in a press (Figure
against the gear head. Use a sleeve
6.01). of the correct size against the bearing
2. Support the bearing cage with metal or inner race (Figure 6.03).
wood blocks.
3. Press the bearing cup into the bore of
bearing cage until cup is flat against the
bottom of bore. Use a sleeve of the
correct size to install bearing cup (Figure
1. SLEEVE 3 SUPPORTS
6.01).
2. BEARING CUP 4. CAGE
4. Use the same procedure for both bearing
cups. Figure 6.01 |1. PRESS 2. SLEEVE 3. SPIGOT BEARING
5. Put the drive pinion in a press, gear Figure 6.03
(teeth) toward the bottom (Figure 6.02).
head
6. Press the inner bearing cone on the shaft
of the drive pinion until the cone is flat
against the gear head. Use a sleeve of
the correct size against the bearing inner
race C. Install the snap ring* into groove in
with snap rin9
6.2. INSTALL ONE-PIECE SPIGOT end ofdrive pinion
BEARING ASSEMBLIES plier (Figure 6.04).
NOTE: Some spigot bearings are fastened
to the drive pinion with a snap ring, some
1. SLEEVE 2. INNER BEARING CONE
are fastened with a peening tool, and
some are a two-piece bearing assembly Figure 6.02
with the inner race pressed on the nose
of the pinion and the outer race pressed
into its bore in the carrier.

1. SPIGOTBEARING 2. SNAP RING

Flgure 6.04

Some Rockwell Camlers do not have the parts described.

Page 38
CTS-5080T CTS-508OT Page 39
 REASSEMBLE
REASSEMBLE
NOTE: Some splgot bearings are held In
5. Put the drive pinion and the tube of the
positlon by peening the end of the drive peen tool in a press, spigot bearing
pinion. Use the following procedure toward the top (Figure 6.07).
(Flgure 6.05). 6. Calculate the amount of pressure that will
be required on the peen tool. See
6.2.1. Peen the Spigot Bearing on Drive INSTALL AND CENTE
specification and example calcultion. THE PUNCH ON THE
Pinion END OF THE PINION
7. Put the punch of the peen tool over the
1. Apply 6,614 Ib. (3,000 kg) pressure on a
375 inch or 10 mm ball. end ofthe pinion and spigot bearing.
Apply the required amount of pressure
2. Peen the end of drive pinion at a on the punch (Figure 6.07).
minimum of five points (Figure 6.05).
Figure 6.05 CAUTION Do not align new points
-

with grooves in end of drive pinion or

in old points. If the new peen polnts
are put in the wrong areas, the spigot
PUT THE
bearing will not be held correctly on
the pinion.
SHAFT OF
PINION INTO
3. When a peen tool (Figure 6.06) and TUBE
press are used (refer to SPECIAL
TOOLS, page 90), calculate the pressure
8. Rotate the punch as many times as
required on the tool as follows. 1. PRESS
minimum of five points.
required for a 2 SPIGOT BEARING
6,614 Ib. (3,000 kg) x amount of balls in
tool = pounds or kilograms
Repeat Step 7 for each point.
NOTE: If a three ball peen tool is used, Figure 6.07
Example: 6,614 Ib. x 3 balls = 19,842
rotate the tool 180° (degrees).
1. PUNCH
pounds
2. TUBE
6.3. INSTALL TWO-PIECE SPIGOT
Figure 6.06 BEARING ASSEMBLIES
NOTE: This procedure applies to some
160 Series single rear axles and rear rear
tandem axles. These axles may also use a
one-piece spigot bearing with a snap
ring retainer.

The inner race of two-plece spigot

bearings must be staked in place on RS
serles axles. Before you stake the
rear
stem to
pinlon, you must heat the pinion
soften It.

A peen tool klt is avallable (refer to

SPECIAL TOOLS, page 90) which
Includes everything requlred to pertorm
this procedure.

Page 41
Page 40 CTS-5080T CTS-5080T
 REASSEMBLE
REASSEMBLE

4. Remove the flame and the heat shield

1.
Apply two stripes of temperature
indicating liquid on the pinion stem from
from the pinion. Let the pinion air cool for
10 minutes. Use a razor blade to remove
the top to the bottom (Figure 6.08). Apply
a green stripe to indicate 400°F and a
the temperature indicating liquid.
blue stripe to indicate 500°F.
CAUTION Do not press or hit di-
2. Put the heating shield over the pinion rectl on the new inner race in Step 5
stem so that you can see the or you will damage the bearing.
temperature indicating liquid through the
hole in the shield (Figure 6.09).
5. Use a press, if available, or a brass
WARNING To protect hammer to install the new inner race. Use
the old inner race as a sleeve. The race is
yourself from injury, wear safety
glasses when you do Steps 3-6. completely seated when you cannot fit a
Wear heat resistant gloves while youu 0.002 inch feeler gauge between the race
Figure 6.08
do Steps 3 and 4. and the pinion shoulder.
NOTE: If you cannot hold the races in
CAUTION- Do not heatthepinion place, try using the staking tool instead of
stem without the heat shield in place. the old race to start the new race on the
Also, do not overheat the pinion stem stem. But, use the old race to completely
or you will weaken the metal which seat the new race.
can cause early failure. Correct heat
NOTE: In Step 6, you do not need to use
ing will take approximately 25-35
seconds, depending on how hot the the plastigage for every stake. Just use it
torch is. until you are sure you are hitting the
punch with the correct force.

3. Light and adjust the torch until the white 6. Put the staking tool over the bearing View A

part of the flame is approximately 1/4 race. Cut a one-inch piece from the
Flgure 6.09 in
inch long. Keep the white part of the green plastigage strip and put
flame approximately 1/8 inch from the between the punch and the staking tool
top of the stem (Figure 6.10). Move the (Figure 6.11-View A). Hit the punch with
flame around the outer diameter of the a two-three pound brass hammer to
top of the pinion stem. The green upset the end of the pinion stem. Then,
temperature indicating liquid will turn remove the strip and measure its
black before the blue liquid does. Heat thickness against the gauge on the
the stem until the blue liquid turns black WHITE PART in. The stnp
wrapper that the strip came VMew B
OF FLAMAE thick.
at a point in the middle of the window. must not be less than 0.003 inch
This thickness indicates that you are
1/4 1. PUNCH
hit the
using enough force when you 2. PLASTIGAGE
then you
punch. If the strip is too thin, 3 STAING TOOL
the stake
must hit the punch harder so
Rotate the tool 4. BEARING INNER AACE
PINION will hold the race in place.
HEATING until there are 5. STAKESs
and repeat this procedure
SHIELD marks around
Figure 6.10 Sixevenly spaced stake Flgure 6.11
the stem (Figure 6.11-View B).

CTS-508OT Page 43
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 REASSEMBLE REASSEMBLE

7. 3. Apply and hold the correct amount of

With a press or a soft mallet and sleeve, pressure to the pinion bearings. Refer to
install the outer race and roller assembly
into its bore in the carrier. Use a sleevve ADJUST PRELOAD OF PINION BEAR--
that is the same size as the outer race INGS, page 85. As pressure is applied,
and press the bearing until it is squarely rotate the bearing cage several times so
against the shoulder in the bottom of its that bearings make normal contact.
bore 4. While pressure is held against the
8. Apply axle lubricant on bearing cups in assembly, wind a
cord around the
the cage and bearing cones. bearing cage several times.
9. Install the drive pinion into the bearing 5. Attach a spring scale to end of cord.
cage. 6. Pull the cord with scale on a horizontal
10.Install the bearing spacer or spacers on line. As the bearing cage rotates, read
pinion shaft against the inner bearing the value indicated on scale. Make a note
cone (Figure 6.12). of reading (Figure 6.13).
NOTE: The spacer or spacers control the NOTE: Do not read starting torque. Read
1. BEARING SPACER
preload adjustment of the drive pinion only the torque value after the cage starts
bearings. 2. BEARING CAGE to rotate. Starting torque will give a false
3. INNER BEARING cONE reading.
11.Install the outer bearing cone on pinion
4. DRIVE PINION
shaft against the spacer (Figure 6.12). 7. Measure the diameter of bearing cagge
NOTE: DO NOT instal pinion seal in
5. OUTER BEARING CONE where the cord was wound. Measure in
Figure 6.12 inches or centimeters (Figure 6.14).
bearing cage. Continue with adjusting
preload of pinion bearings. 8. Divide the dimension in half to get the
radius. Make a note of radius dimension. Figure 6.14

6.4. ADJUST PRELOAD OF PINION 9. Use the following procedure to calculate

BEARINGS the bearing preload (torque).
Refer to ADJUST PRELOAD OF PINION
BEARINGS, page 85, for the proper
Pounds puled x Radius (inches)=
in-lbs. preload x .113 Nem preload
setting 1. PRESS
OR
NOTE: If a press is not available, or the 2. SLEEVE Kilograms pulled x Radius (centimeters)
press does not have a pressure gauge, =
kg-cm preload x .098 Nom preload
=

use the yoke or flange method to adjust

preload. The spacer or spacers control
Examples
Reading from spring scale = 7.5 lbs.
the preload adjustment of the drive pinion
(3.4 kg)
bearings. Diameter of bearing cage 6.62 inches
1. Put the drive and cage
(16.8 cm)
pinion assembly Radius of bearing cage = 3.31 inches
a press, gear head (teeth) toward the
inbottom. (8.4 cm)
7.5 Ib. x 3.31 in. = 24.8 in. -Ib.
2. sleeve Flgure 6.13
Install a
of the
correct size against
the inner race of the outer bearing preload x .113 2.8 Nem preload OR
(Figure 6.13). 3.4 kg x 8.4 cm =2.8
28.6Nom
kg-cm
preload x .098 preload

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 REASSEMBLE
REASSEMBLE
10.If the preload (torque) of pinion bearings
is not within specifications, do
5. Tighten the nut on drive pinion to the
the correct torque value (Figure 6.17). Refer
following
to 8.
procedure then repeat Steps 4 to the TORQUE CHART, page 86.
6. Remove the yoke or flange bar.
To increase preload, install a thinner
7. Attach a torque wrench on the drive READ
bearing spacer. To decrease preload,
install a thicker bearing spacer. pinidon n Rotate the drive pinion and TORQUE
read the value indicated on torque VALUE
11.Check the bearing preload with the drive
pinion and cage assembly installed in the
wrench (Figure 6.18).

carrier. Follow the procedures to adjust 8. If the preload (torque) of pinion bearings
preload of pinion bearings, yoke or is not within specifications, remove the
pinion and cage assembly from carrier.
flange method.
Do the following procedure, then repeat
1. PRESS
6.4.1. Yoke or Flange Method Steps 1 to 7.
2. INPUT FLANGE Figure 6.18
1. Install the input yoke nut A. To increase preload, install a thinner
or
flange, and Figure 6.15
washer on the drive pinion. The yoke or bearing spacer.
flange MUST be against the outer B. To decrease preload, install a thicker
bearing.
bearing spacer.
NOTE: If the fit between the yoke or
flange splines and drive pinion splines is 9. After adjusting preload of pinion
bearings, remove the drive pinion and
tight, use a press to install the yoke or
bearing cage from carrier. Refer to
flange (Figure 6.15). REMOVE THE DRIVE PINION AND
BEARING CAGE FROM CARRIER, page
Ifa press is not available, use the 18.
three-piece pilot tool for installation.
Refer to INSTALL TIGHT FIT YOKES,
10.Ifthe carrier has a cover and seal
page 35. assembly over the bearing cage, install a
new seal into cover as follows.
CAUTION - Do not install tight fit
Figure 6.16 A. Apply Lubriplate or grease used for
yokes or
flanges on shafts using a
hammer or mallet. A hammer or mal
let will damage the yoke or flange
wheel bearings to the seal lips and
cavities between lips. REFER TO
-
GROUP 10 LUBRICATION.
and/or bearing.
B. Apply a sealing compound on the
2. Temporarily install the drive pinion and Outer diameter of seal.
cage assembly in the carrier. Do not
install shims under the bearing cage C. Put the cover in a press, large
(Figure 6.16). diameter toward the top.
3. Install the bearing cage to carrier FLANGE D. Support the cover under the smal
cap BAR
screws. Washers are not required at this SHOWN diameter opening with metal or wood 1. PRESS 4. SLEBVE
time. Tighten the capscrews hand tight. blocks (Figure 6.19) SEAL 5. COVE
4. Fasten a yoke or flange bar to the input E. Press the seal into cover until seal is 3. SUPPORT
yoke or flange. The bar will hold the drive
Figure 6.17 against the bottom of bore. Use a
fiat
pinion in position when the nut is sleeve or seal driver of the correct Figure 6.19
tightened (Figure 6.17) size that fits against the metal retainer
of seal (Figure 6.19).
Some Rockwell Carriers do not have the parts described.
Page 46 CTS-5080T CTS-5080T Page 47
 REASSEMBLE REASSEMBLE

NOTE: Ifa press is not availlable, use a

mallet and the
the seal
sleeve or driver to Install
(Figure 6.20).

WARNING Wear safe eye

protection. Do not hlt steel parts or
tools with a steel hammer. Parts or
tools can break and cause injury.
E. Press the seal into bearing cage until
11.If the pinion seal mounts directly into the flange of seal is flat against the top of
bearing cage, install a new triple-lip seal bearing cage. Use a sleeve or seal
as follows: 1 cOVER
driver of the correct size that fits
2. SEAL DRIVER
A. The old triple-lip seal can be against the metal flange of seal. The
Flgure 6.20
installed into the bearing cage if the diameter of the sleeve or driver MUST
seal is not worn or damaged. Refer to be larger than the diameter of the
DISASSEMBLE THE DRIVE PINION APPLY flange (Figure 6.22).
AND BEARING CAGE, page 20. LUBRICANT
TO SEAL APPLY
B. Apply the same lubricant used in the BORE GREASE
axle housing to the outer surface of
the seal and the seal bore in the
bearing cage (Figure 6.21).
CAUTION- Make sure that the seal
1. PRESSs 4. BEARING CAGE
lips are clean and free from dirt and
particles that will cause a leak 2 SLEEVE 5. DRIVE PINION
between the yoke and the seal. 3. SEAL 6 SUPPORT
1. TAIPLE LIP
SEAL Figure 6.22
2. BEARING CAGE
C. On reused seals, apply Lubriplate or 3. DRIVE PINION
wheel bearing grease to the seal lip. SDRAL ER
Figure 6.21
D. Put the drive pinion and cage
assembly in a press, seal bore toward NOTE: If a press is not available, use a
the top. mallet and the sleeve or driver to install
the seal (Figure 6.23).

WARNING- Wear safe eye

protection. Do not hlt steel parts or
tools with a steel hammer. Parts or
tools can break and cause Injury.

Flgure 6.23

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