1.

Disassembly Differential 777D

a. Tool yang dibutuhkan

b. Proses disassembling differential

1. Position the differential and bevel gear onto Tooling (A), as shown

2. Remove bolts (1), the washers, and locks (2)

3. Remove bolts (3) and washers (4). Remove bearing caps (5) and (6) from the differential carrier
assembly
4. Attach a suitable lifting device to the differential. The weight of the differential is approximately
249 kg (550 lb)

5. Use Tooling (B) (not shown) to remove two adjustment rings (8) from the differential. Remove
adjustment rings (8)
6. Raise the differential and remove bearing cages (7)
7. Use a suitable press (not shown) to remove bearing cups (9) from bearing cages (7)

8. Remove the differential from the differential carrier assembly. Position the differential with the
teeth of the bevel gear in the upright position
9. Install Tooling (C) onto bearing cone (10). Position a suitable lifting device on Tooling (C). Use a
suitable lifting device to secure Tooling (C)

10. Use Tooling (C) to remove bearing cone (10). Remove bearing cone (10)

11. Turn over the differential. Position the differential onto suitable blocks, as shown
12. Install Tooling (C) onto bearing cone (11). Position a suitable lifting device on Tooling (C). Use a
suitable lifting device to secure Tooling (C)
13. Use Tooling (C) to remove bearing cone (11). Remove bearing cone (11)
14. Attach a suitable lifting device to the differential. Remove locknuts (13) and hard washers (14).
Use Tooling (F) to separate the differential from differential bevel gear (12)

15. Position the differential onto suitable blocks, as shown

16. Attach a suitable lifting device on the differential, as shown. The weight of differential housing
(15) is approximately 50 kg (110 lb). Remove nuts (16) and the hard washers. Remove
differential housing assembly (15) from differential housing assembly (17).

17. Remove thrust washer (18) from differential bevel gear (19). Remove differential bevel gear (19)
18. Use two people to remove differential pinion (20) and differential spider (21) as an assembly.
The weight of differential pinion (20) and differential spider (21) is approximately 41 kg (90 lb)
19. Remove differential pinion (20) from differential spider (21)

20. Secure Tooling (D) onto a suitable vise

21. Position differential pinion (20) onto Tooling (D). Align notch of the retainer with the pin on
Tooling (D)

22. Install the nut of Tooling (D)

23. Bend the tab of nut lock (22) so that nut lock (22) does not engage nut (23)
24. Use Tooling (E) to loosen nut (23). Remove nut (23) and nut lock (22)
25. Remove bearing cone (24) and differential pinion (20) from the retainer

26. Remove bearing cups (25) from differential pinion (20)

27. Remove spacer (27) and bearing cone (28) from retainer (26).
28. Remove the nut from Tooling (D). Remove retainer (26) from Tooling (D).
29. Repeat Steps 17 through 28 for the three remaining differential pinions.

30. Remove differential bevel gear (29) and thrust washer (30) from differential housing assembly
(17)

31. Position differential carrier assembly (32) onto Tooling (A) (not shown). The weight of
differential carrier assembly (32) is approximately 272 kg (600 lb).
32. Use two people to remove bearing cage (34) from differential carrier assembly (32). The weight
of bearing cage (34) is approximately 27 kg (60 lb).
33. Remove two bolts (33) that are 180 degree apart. Use Tooling (G) to remove bearing cage (34).
Remove remaining bolts (33) and bearing cage (34)
34. Remove seal assembly (35), bearing cup (36), and O-ring seal (37) from bearing cage (34)

35. Remove shims (38) from the differential carrier assembly.

36. Use two people to remove bevel pinion assembly (39) from the differential carrier assembly. The
weight of pinion assembly (39) is approximately 45 kg (100 lb). Remove bevel pinion assembly
(39)

37. Remove wear sleeve (40) from pinion assembly (39).

38. Use Tooling (R) and Tooling (S) to remove bearing cone (41). Remove bearing cone (41)

39. Use Tooling (R) and Tooling (S) to remove bearing cone (42). Remove bearing cone (42).

40. Remove bearing cup (43) from the differential carrier assembly.
2. Assembling Differential 777D
a. Tool yang dibutuhkan

b. Proses assembling Differential

Note: Check the O-ring seals, the seals, and the gaskets for wear or damage. Replace the
components if necessary.

Note: When assembling the pinion assembly, ensure that all bearing cups and the bearing cones
are fully seated against the shoulders. Do not install the pinion lip seal until after the final
adjustment is complete.

Note: Do not start bearing setting process until all of the components in the assembly are at the
same temperature ± 3°C (± 5°F) of ambient temperature. (Typically the wait time after
assembling bearings that have been cooled or heated is minimum of 8 hours.)

1. Raise the temperature of bearing cone (42) to a maximum temperature of 135 °C (275 °F). Install
bearing cone (42) onto the pinion assembly.

2. Raise the temperature of bearing cone (41) to a maximum temperature of 135 °C (275 °F). Install
bearing cone (41) onto the pinion assembly.

3. Use a suitable press to install wear sleeve (40). Install wear sleeve (40)
4. Position the differential carrier assembly onto Tooling (A) (not shown).
5. Lower the temperature of bearing cup (43) to a maximum of −54 °C (−65 °F). Install bearing cup
(43) into the differential carrier assembly.
Note: Ensure that the bearing cup and the bearing cones are fully seated against the shoulders.

6. Use two people to install pinion assembly (39) into differential carrier assembly (32). The weight
of pinion assembly (39) is approximately 45 kg (100 lb). Install pinion assembly (39).

7. Lower the temperature of bearing cup (36) to a maximum of −54 °C (−65 °F). Install bearing cup
(36) in bearing cage (34).
Note: Ensure that the bearing cup and the cones are fully seated against the shoulders.

8. Install the shim pack. The starting thickness of the shim pack should be 0.83 mm (0.033 inch).
9. Position bearing cage (34) vertically on differential carrier assembly (32).
10. Install four bolts (33) equally spaced across bearing cage (34).
a. Tighten bolts (33) to a torque of 215 ± 40 N·m (159 ± 29 lb ft).
11. Install Tooling (H) into the pinion assembly.
12. Using Tooling (H), rotate the pinion assembly for five full revolutions in the clockwise direction
and counter clockwise direction. Measure the torque used to rotate the pinion. Rotate the
pinion slowly (20-30 RPM) while the measurement is made.
13. If the measured torque to rotate the pinion is not within 10 ± 3 N·m (89 ± 26 lb in), adjust the
shims and repeat Step 10 through Step 12 until the proper torque value is achieved to seat the
bearings.
14. While keeping the differential in the vertical position, loosen bolts (33).
15. To set the bearings, adjust the shim pack and repeat Step 10 through Step 12. If the torque is
not within 4 ± 0.6 N·m (35 ± 5 lb in), repeat Step 10 through Step 12 and adjust the shim pack,
until the proper torque value is achieved to set the bearings.
16. Remove bearing cage (34). Do not move the pinion assembly
Note: Do not install the O-ring seal or the seal assembly in bearing cage (34) now.
Note: The seal assembly is not to be installed until after the adjustment is made.
17. Use Tooling (J) to install seal assembly (35). Seal assembly (35) should be oriented with the lip
seal toward Tooling (J).
18. Position bearing cage (34) in a suitable press. Install the seal assembly into bearing cage (34)

19. Install shims (38) that were determined in Step 15

20. Lubricate seal assembly (35) with the lubricant that is being sealed.
21. Install O-ring seal (37)

22. Attach Tooling (L) and a suitable lifting device (not shown) to bearing cage (34).
23. Install bearing cage (34) on differential carrier assembly (32). Apply Tooling (K) to bolts (33).
Install bolts (33) and the washers. Tighten bolts (33) to a torque of 270 ± 40 N•m (200 ± 30 lb ft).
24. Dimension (X) should be 85.19 ± 0.41 mm (3 ± 0.02 inch)

25. Position differential housing assembly (17) on blocks, as shown.

26. Install thrust washer (30) and differential bevel gear (29) in differential housing assembly (17).
Note: Align slots in the thrust washer with the dowels in differential housing assembly (17).

27. Secure Tooling (D) in a suitable vise.

28. Install retainer (26) on Tooling (D). The groove in retainer (26) should be in alignment with the
pin in Tooling (D).

29. Install the nut of Tooling (D).

30. Install bearing cone (28) and spacer (27) on retainer (26)

31. Position differential pinion (20) in a suitable press. Use Tooling (L) to install bearing cups (25).
32. Install differential pinion (20) on the retainer.
33. Install bearing cone (24)

34. Install nut lock (22). Make sure that nut lock (22) is installed with the inside tab facing up
towards nut (23). Refer to Illustration 18. Install nut (23).

35. Tighten nut (23) to a torque of 70 ± 15 N•m (52 ± 11 lb ft).

36. Bend the tabs on nut lock (22) to secure nut (23). Have at least two or more tabs pulled up
tightly against nut (23). Refer to Illustration 19.

37. Remove from Tooling (D).

38. Repeat Steps 27 through 36 for the three remaining differential pinions

39. Position a suitable lifting device on differential spider (21). Install differential spider (21) and four
differential pinions (23) as an assembly in differential housing assembly (17). Align grooves in the
pinion retainers with the dowels in differential housing assembly (17).
 40. Apply grease to the back side of thrust washer (18). Install thrust washer (18) on differential
housing (15). Align grooves in thrust washer (18) with the dowels in differential housing (15).

41. Install differential and bevel gear (19) on the differential pinions.

42. Install differential housing assembly (15) onto differential housing assembly (17).
Note: There are two types of differentials, refer to the information below:
a. Install the 8 bolts and the hard washers. Install 8 locknuts (16A). Tighten locknuts (16A) to a
torque of 395 ± 40 N·m (291 ± 30 lb ft).

b. Use Tooling (P) on bolts (16B). Install the 8 bolts and the hard washers. Tighten bolts (16B) to a
torque of 350 N•m (258 lb ft). Turn the bolts an additional 60 degrees.
Note: Bolts (16B) are one time use only.

43. Support the differential in "V" block type supports.

44. Install Tooling (H) into the differential bevel gear. Turn the gears clockwise by two revolutions.
Turn the gears counterclockwise by two revolutions. The maximum torque that is required to
turn the gears must not exceed 35 N•m (26 lb ft). If the maximum torque that is required to turn
the gears is more than 35 N•m (26 lb ft), the differential must be reassembled

45. Position differential and bevel gear (12) on suitable blocks, as shown.
 Note: Check the bolts for wear. If necessary, use new bolts

46. Prior to assembling the differential group, assemble ring gear (12) to the housing. Use the ring
gear as a guide and ream one hole to a diameter of 19.0500 ± 0.0130 mm (0.75000 ± 0.00051
inch). Assemble one bolt and ream 13 holes to a diameter of 19.05 ± 0.013 mm (0.75000 ±
0.00051 inch). Install the remainder of the bolts. Install washers (14) and locknuts (13). Tighten
the nuts to a torque of 440 ± 40 N·m (325 ± 30 lb ft).

47. Attach Tooling (L) and a suitable lifting device (not shown) to bearing cage (34).

48. Raise the temperature of bearing cone (11) and bearing cone (10) to a maximum temperature of
135 °C (275 °F).

49. Install bearing cone (11) onto the differential. Bearing cone (11) must touch the flat surface of
differential housing assembly (38)

50. Turn over the differential.

51. Install bearing cone (10) onto the differential. Bearing cone (10) must touch the shoulder of the
differential.
Note: Do not start Bearing setting process until all of the components in the assembly are at the
same temperature ± 3°C (± 5°F) of ambient temperature. (Typically the wait time after
assembling bearings that have been cooled or heated is minimum of 8 hours.)

52. Use a suitable press to install bearing cups (9) into bearing cages (7)
53. Position a suitable lifting device on the differential. The weight of the differential is
approximately 249 kg (550 lb). Install bearing cages (7) on the differential. Install the bearing
cages (7) with the dowel holes in the up position.

54. Lower the differential to the differential carrier assembly. Do not rest the differential on the
differential carrier assembly.

55. Install one adjustment ring (8) on each end of the differential. Hand tighten adjustment nuts (8)
to keep the differential group in place, do not apply torque

56. Install bearing caps (6) and (5). The dowels must align with the holes in bearing cages (7).
57. Tighten the bolts that secure bearing caps (6) and bearing caps (5) to a torque of 70 ± 15 N·m
(52 ± 11 lb ft). Do not tighten the bolts to full torque

58. Use Tooling (M) to attach the differential and bevel gear to Tooling (A). The teeth of the
differential bevel gear must be positioned in the up position.
59. Hand tighten the top adjustment nut until the nut contacts the bearing surface. Loosen the top
adjustment by one notch.
60. Position Tooling (N) on the differential carrier assembly, as shown in Illustration 34. Position the
measurement probe of the dial indicator perpendicular to the heel of the gear tooth being
measured. Illustration 35 shows an example of the heel of the bevel gear and the perpendicular
position of the dial indicator.
61. Take three backlash measurements around large bevel gear at locations 120 degrees apart. All
three backlash measurements should be 0.41 ± 0.13 mm (0.016 ± 0.005 inch).
62. Use Tooling (B) (not shown) to tighten the bottom adjustment nut and repeat step 58 through
step 61 until a backlash of 0.41 ± 0.13 mm (0.016 ± 0.005 inch) exists between the differential
bevel gear and the pinion assembly.
63. Position Tooling (N) on the differential carrier assembly as shown in Illustration 37. Measure
dimension (Z) in the same location until the preload process is complete.
64. Use Tooling (B) to adjust the top adjustment ring so that dimension (Z) increases by 0.64 to 0.76
mm (0.025 to 0.030 inch) to seat the bearing.
65. Rotate the differential bevel gear by five revolutions in each direction.
66. Use Tooling (B) to loosen the top adjustment ring so that no tension is on the bearings.
67. Use Tooling (B) to adjust the top adjustment ring so that dimension (Z) increases by .27 ± 0.05
mm (0.011 ± 0.002 inch) to set the bearing

68. Position Tooling (N) on the differential carrier assembly, as shown in Illustration 34. Position the
measurement probe of the dial indicator perpendicular to the heel of the gear tooth being
measured. Illustration 39shows an example of the heel of the bevel gear and the perpendicular
position of the dial indicator.
69. Take three backlash measurements around the large bevel gear at locations 120 degrees apart.
All three backlash measurements should fall within the specified backlash range of 0.41 ± 0.13
mm (0.016 ± 0.005 inch).
70. If the backlash needs adjusted, adjust the adjustment nuts equally Using Tooling (B) (not
shown). Adjust the adjustment nuts until a backlash of 0.41 ± 0.13 mm (0.016 ± 0.005 inch)
exists between the differential bevel gear and the pinion assembly.
Note: If the top adjustment ring is loosened, the bottom adjustment nut should be tightened by
the same amount. If the adjustment nuts are not adjusted equally, then the bearing preload will
be incorrect.

71. Install locks (2) and bolts (1) on the bearing caps
72. Tighten bolts (3) to a torque of 1100 ± 150 N·m (810 ± 110 lb ft)