NMWR 9-2520-585 front and rear differential 15Jan13.pdf

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

DIFFERENTIAL, FRONT AND REAR

HMMWV FOV

(NSN 2520-01-291-2975) P/N 12338415-3

(NSN 2520-01-358-3160) P/N 12342615

(NSN 2520-01-416-5217) P/N RCSK17305

(NSN 2520-01-498-9104) P/N 12469309

(NSN 2520-01-574-4828) P/N 2011412-1

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCLMPP/ TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*This manual supersedes NMWR 9-2520-585, dated 01 June 20 10, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

15 JANUARY 2013

*NMWR 9-2520-585

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in death or serious injury to personnel. Refer to FM 4-25.11 for first aid instructions.

• Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

• Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

• Differential oil cooler assembly is under high pressure. Release air from assembly by using the air draincock before disconnecting any air lines. Air is under pressure and creates danger to eyes. Wear safety goggles to prevent serious personal injury. Seek medical attention in the event of an injury.

• Leaking or spilled oil or GAA may cause a slip and fall hazard. Clean any leaking or spilled oil or GAA immediately, using suitable fluid absorbent materials. Dispose of contaminated cloths, rags, or cleaning materials in accordance with local procedures and plans. Failure to comply may result in injury to personnel.

Seek medical attention in the event of an injury.

• Do not use compressed air to dry bearings.

• Direct all personnel to stand clear during hoisting operations. A heavy swinging load can be extremely dangerous.

• When steam cleaning, protective clothing must be worn.

• Degreasing solvent is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when solvent is used. Use only in well-ventilated areas.

• Use caution when handling heavy parts. Provide adequate support and use assistance during procedure.

• Wear adequate protective goggles/shields to prevent injury from airborne fragments.

NMWR 9-2520-585

a/b blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes NMWR 9-2520-585, dated 01 June 2010, including all changes. Zero in the Change No. column indicates an original page or work package.

Original:15 JANUARY 2013

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 22 AND

TOTAL NUMBER OF WORK PACKAGES IS 19,

CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front cover Warning Summary (2 pgs) i – iv (4 pgs) Chapter 1 title page (2 pgs) WP 0001 (4 pgs) WP 0002 (2 pgs) Chapter 2 title page (2 pgs) WP 0003 (10 pgs) WP 0004 (10 pgs) WP 0005 (40 pgs) WP 0006 (2 pgs) WP 0007 (6 pgs) WP 0008 (2 pgs) WP 0009 (2 pgs)

Page/WP No. Change No.

WP 0010 (4 pgs) WP 0011 (8 pgs) Chapter 3 title page (2 pgs) WP 0012 (8 pgs) WP 0013 (6 pgs) WP 0014 (2 pgs) WP 0015 (2 pgs) Chapter 4 title page (2 pgs) WP 0016 (2 pgs) WP 0017 (2 pgs) WP 0018 (2 pgs) WP 0019 (2 pgs) Back cover

NMWR 9-2520-585

A/B blank i

U.S. ARMY TACOM LIFE CYCLE

MANAGEMENT COMMAND

15 JANUARY 2013

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

DIFFERENTIAL, FRONT AND REAR

HMMWV FOV

(NSN 2520-01-291-2975) P/N 12338415-3

(NSN 2520-01-358-3160) P/N 12342615

(NSN 2520-01-416-5217) P/N RCSK17305

(NSN 2520-01-498-9104) P/N 12469309

(NSN 2520-01-574-4828) P/N 2011412-1

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and blank forms) through the Internet, on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727,6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or commercial (586) 282-1856. A reply will be furnished to you.

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCLMPP/ TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*This manual supersedes NMWR 9-2520-585, dated 01 June 2010, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

*NMWR 9-2520-585

i

TABLE OF CONTENTS

WP Sequence No./Page No.

CHAPTER 1. GENERAL INFORMATION AND EQUIPMENT DESCRIPTION AND DATA

General Information ......................................................................................................................... WP 0001

Equipment Description and Data .................................................................................................... WP 0002

Figure 1. Differential. .................................................................................................................. WP 0002-1

Table 1. Front and Rear Differential. ......................................................................................... WP 0002-1

CHAPTER 2. MAINTENANCE INSTRUCTIONS

Front and Rear Differentials Disassembly ...................................................................................... WP 0003

Figure 1. Output Shaft/Differential Assembly. ........................................................................... WP 0003-1

Figure 2. Output Shaft/Differential Assembly. ........................................................................... WP 0003-2

Figure 3. Output Shaft/Differential Assembly. ........................................................................... WP 0003-2

Figure 4. Differential Cover. ....................................................................................................... WP 0003-3

Figure 5. Bearing Caps Marking. ............................................................................................... WP 0003-4

Figure 6. Differential Housing Spreader. .................................................................................... WP 0003-5

Figure 7. Differential Case. ......................................................................................................... WP 0003-6

Figure 8. Pinion Assembly. ......................................................................................................... WP 0003-7

Figure 9. Bearing Cup Installation. ............................................................................................ WP 0003-8

Figure 10. Ring Gear. ................................................................................................................. WP 0003-9

Figure 11. Differential Side Bearings. ........................................................................................ WP 0003-9

Figure 12. Rear Pinion Bearing. ................................................................................................. WP 0003-10

Front and Rear Differentials Cleaning and Inspection ................................................................... WP 0004

Figure 1. Differential Housing. ................................................................................................... WP 0004-4

Figure 2. Gears. ........................................................................................................................... WP 0004-4

Figure 3. Differential Components. ............................................................................................ WP 0004-5

Figure 4. Test Equipment Leak Check. ...................................................................................... WP 0004-6

Figure 5. Test Equipment Installation. ....................................................................................... WP 0004-7

Figure 6. Test Equipment Final Preparation. ............................................................................. WP 0004-8

Front and Rear Differentials Assembly ........................................................................................... WP 0005

Figure 1. Differential Cover Installation. .................................................................................... WP 0005-2

Figure 2. Bearing Cup Installation. ............................................................................................ WP 0005-3

Figure 3. Pinion Bearing Cup Installation. ................................................................................. WP 0005-4

Figure 4. Arbor Installation. ....................................................................................................... WP 0005-5

Figure 5. Pinion Shim Measurement. ......................................................................................... WP 0005-6

Figure 6. Dial Indicator Reading. ............................................................................................... WP 0005-7

Figure 7. Arbor Installation. ....................................................................................................... WP 0005-8

Figure 8. Pinion Bearing Cup Installation. ................................................................................. WP 0005-9

Figure 9. Pinion Shim and Bearing Cup Installation. ................................................................ WP 0005-10

Figure 10. Pinion Gear. ............................................................................................................... WP 0005-11

Figure 11. Pinion and Yoke Installation. ................................................................................... WP 0005-12

Figure 12. Differential Bearing and Seal Installation. ............................................................... WP 0005-13

Figure 13. Pinion and Yoke Installation. ................................................................................... WP 0005-14

Figure 14. Pinion and Yoke Installation. ................................................................................... WP 0005-15

Figure 15. Differential Gear Unit. .............................................................................................. WP 0005-16

Figure 16. Gear Unit Installation. ............................................................................................... WP 0005-17

Figure 17. Gear Unit Installation. ............................................................................................... WP 0005-18

Figure 18. Side Bearing Shim Measurement. ............................................................................ WP 0005-19 ii

TABLE OF CONTENTS - CONTINUED

CHAPTER 2. MAINTENANCE INSTRUCTIONS - Continued

Figure 19. Gear Unit Installation/Bearing Shim Measurement. ..................................................WP 0005-20

Figure 20. Gear Unit Installation. ............................................................................................... WP 0005-21

Figure 21. Ring Gear Installation. .............................................................................................. WP 0005-22

Figure 22. Differential Spreader. ................................................................................................ WP 0005-23

Figure 23. Differential Gear Unit Installation. ........................................................................... WP 0005-24

Figure 24. Differential Spreader. ................................................................................................ WP 0005-24

Figure 25. Differential Gear Unit Installation. ........................................................................... WP 0005-25

Figure 26. Ring Gear Backlash. ................................................................................................. WP 0005-26

Figure 27. Differential Gear Unit Installation. ........................................................................... WP 0005-27

Figure 28. Differential Spreader. ................................................................................................ WP 0005-28

Figure 29. Differential Gear Unit Installation. ........................................................................... WP 0005-29

Figure 30. Differential Spreader. ................................................................................................ WP 0005-30

Figure 31. Differential Gear Unit Installation. ........................................................................... WP 0005-30

Figure 32. Ring Gear Backlash. ................................................................................................. WP 0005-31

Figure 33. Differential Gear Unit Installation. ........................................................................... WP 0005-32

Figure 34. Differential Spreader. ................................................................................................ WP 0005-33

Figure 35. Differential Spreader. ................................................................................................ WP 0005-34

Figure 36. Differential Gear Unit Installation. ........................................................................... WP 0005-35

Figure 37. Differential Gear Unit Installation. ........................................................................... WP 0005-36

Figure 38. Differential Spreader. ................................................................................................ WP 0005-37

Figure 39. Differential Cover Installation. .................................................................................. WP 0005-38

Figure 40. Output Shaft Bearing Installation. ............................................................................ WP 0005-39

Figure 41. Axle Shaft Installation. ............................................................................................. WP 0005-39

Figure 42. Axle Shaft Seal Installation. ..................................................................................... WP 0005-40

Figure 43. Output Flange Installation. ........................................................................................ WP 0005-40

Preservation, Packaging, and Marking ............................................................................................ WP 0006

Preparation for Storage or Shipment .............................................................................................. WP 0007

Figure 1. Lubrication. .................................................................................................................. WP 0007-2

Figure 2. Placing Differential in Container. ............................................................................... WP 0007-3

Figure 3. Placing Differential in Container. ............................................................................... WP 0007-4

Table 1. Final Inspection Report (FIR). ..................................................................................... WP 0007-5

Quality Assurance Requirements .................................................................................................... WP 0008

Illustrated List of Manufactured Items Introduction ...................................................................... WP 0009

Table 1. Manufactured Items Part Number Table of Contents. ................................................ WP 0009-1

Manufactured Oil Cooler Tester ..................................................................................................... WP 0010

Figure 1. Transfer Case Oil Cooler Tester. ................................................................................ WP 0010-2

Table 1. Materials. ....................................................................................................................... WP 0010-2

Torque Limits .................................................................................................................................. WP 0011

Figure 1. Measuring Screw Diameter. ........................................................................................ WP 0011-1

Figure 2. Capscrew Head Markings. .......................................................................................... WP 0011-1

Figure 3. Measuring Screw. ........................................................................................................ WP 0011-2

Table 1. Torque Limits for Dry Fasteners. ................................................................................ WP 0011-3 iii

TABLE OF CONTENTS - CONTINUED

CHAPTER 2. MAINTENANCE INSTRUCTIONS - Continued

Table 2. Torque Limits for Wet Fasteners. .................................................................................WP 0011-4

Table 3. Torque Limits for Metric Fasteners. ............................................................................ WP 0011-5

Table 4. Torque Specifications for Differentials. ....................................................................... WP 0011-7

CHAPTER 3. PARTS INFORMATION

Repair Parts and Special Tools List (RPSTL) Introduction ........................................................... WP 0012

Table 1. SMR Code Explanation. ............................................................................................... WP 0012-1

Table 2. Source Code Explanation. ............................................................................................ WP 0012-2

Table 3. Maintenance Code Explanation. ................................................................................... WP 0012-4

Table 4. Maintenance Code Explanation. ................................................................................... WP 0012-4

Table 5. Recoverability Code Explanation. ................................................................................ WP 0012-5

Axle Differential .............................................................................................................................. WP 0013

Figure 1. Axle Differential. ......................................................................................................... WP 0013-2

National Stock Number Index ......................................................................................................... WP 0014

Part Number Index .......................................................................................................................... WP 0015

CHAPTER 4. SUPPORTING INFORMATION

References ........................................................................................................................................ WP 0016

Expendable and Durable Items List ................................................................................................ WP 0017

Table 1. Expendable and Durable Items List. ............................................................................ WP 0017-2

Tool Identification List .................................................................................................................... WP 0018

Table 1. Tool Identification List. ................................................................................................ WP 0018-2

Mandatory Replacement Parts List ................................................................................................. WP 0019

Table 1. Mandatory Replacement Parts List. ............................................................................. WP 0019-2 iv

CHAPTER 1

GENERAL INFORMATION AND EQUIPMENT

DESCRIPTION AND DATA

FOR

DIFFERENTIAL, FRONT AND REAR

HMMWV FOV

NSN 2520-01-291-2975, P/N 12338415-3

NSN 2520-01-358-3160, P/N 12342615

NSN 2520-01-416-5217, P/N RCSK17305

NSN 2520-01-498-9104, P/N 12469309

NSN 2520-01-574-4828, P/N 2011412-1

SUSTAINMENT MAINTENANCE

GENERAL INFORMATION

SCOPE

This NMWR covers the repair of the front and rear differentials, NSN 2520-01-291-2975, P/N 12338415-3;

NSN 2520-01-358-3160, P/N 12342615; NSN 2520-01-416-5217, P/N RCSK17305; NSN 2520-01-498-9104, P/N 12469309; and NSN 2520-01-574-4828, P/N 2011412-1. These differentials are used in the High Mobility Multipurpose Wheeled Vehicle (HMMWV). In case of conflict with other information, the data contained in this NMWR shall take precedence. The condition of the differential after rebuild shall be that utility and performance are returned to a near-zero-time/near-zero-miles or like-new condition.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards. Components that are found to be worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

The procedures contained in this NMWR describe disassembly, inspection, repair, and assembly to ensure a product that is serviceable and issuable to all customers without limitation, Condition Code A.

Each repair activity shall, in accordance with the terms and conditions set forth herein, furnish equipment, facilities, and services required to perform inspections and complete repair of the front and rear differentials.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual;

DA PAM 738-751, Functional Users Manual for The Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your front or rear differentials need improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

NMWR 9-2520-585 0001

0001-1

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army materiel to prevent enemy use can be found in TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use.

PREPARATION FOR STORAGE OR SHIPMENT

To prepare the front and rear differentials for storage or shipment, refer to WP 0007. Additional information can be found in TM 746-10, General Packaging Instructions for Field Use, Marking, Packing, and Shipment of Supplies and Equipment.

Perform packing, packaging, preservation, and marking requirements in accordance with Special Packaging Instructions (SPI).

The applicable SPI can be found at https://www.ilsc.army.mil/tdps/index.asp by searching for front or rear differential NSN or NIIN.

An NSN or part number must be entered at the query screen. An image reviewer will be needed to view images. The viewer can be downloaded from the website by going to Help and following the directions.

LIST OF ABBREVIATIONS/ACRONYMS

Abbreviations and acronyms appearing in this manual are defined in the paragraph from where they first appear, after which only the abbreviation or acronym is used. The following is a quick-reference list of all abbreviations and acronyms and their corresponding word or compound term used in this manual.

AEPS–Army Electronic Product Support

CAGEC–Commercial and Government Entity Code

CPC–Corrosion Prevention and Control

ECP–Engineering Change Proposal

EIR–Equipment Improvement Recommendations

FOV–Family of Vehicles

HMMWV–High Mobility Multipurpose Wheeled Vehicle

NMWR–National Maintenance Work Requirement

NSN–National Stock Number

OEM–Original Equipment Manufacturer

P/N–Part Number

QA–Quality Assurance

QTY–Quantity

RPSTL–Repair Parts and Special Tool List

SMR–Source, Maintenance, and Recoverability

TACOM–Tank-automotive and Armaments Command

TAMMS–The Army Maintenance Management System

TAMMS-A–The Army Maintenance Management System-Aviation

TM–Technical Manual

UOC–Usable On Code

WP–Work Package

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If quality of material requirements are not stated in this NMWR, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to these front or rear differentials.

ENGINEERING CHANGE PROPOSALS (ECPs)

Engineering Change Proposals (ECPs) will be submitted in accordance with AR 70-1 Army Acquisition Policy, directly to Commander, U.S. Army TACOM Life Cycle Management Command, ATTN:

AMSTA-LCC-HHM, Mail Stop 420, 6501 E. 11 Mile Road, Warren, Michigan 48397-5000. A reply will be furnished to you.

0001-2

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this NMWR will be processed in accordance with ISO 9000 Series standards or equivalent.

MOBILIZATION REQUIREMENTS

All rebuild/repair procedures contained within this NMWR are required to return the front and rear differentials to a serviceable condition.

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of overhaul while taking into consideration cost factors. A determination shall be made on all subassemblies/assemblies to replace worn or damaged components which are available in supply, if acquisition cost is less than the cost to repair and restore to the NMWR standard. The cost to repair/restore any individual item with an established Maintenance Expenditure Limit (MEL) to the NMWR standard shall not exceed the MEL, unless a waiver has been approved in accordance with AMC-R 750-51. This requirement does not apply to items exempted from MEL in accordance with AMC-R 750-51

END OF WORK PACKAGE

0001-3/4 blank

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

Differentials transmit driving power, via halfshafts and geared hubs, to left and right wheels. The differential ensures power is applied to the wheel having traction, regardless of which wheel is slipping.

EQUIPMENT DATA

Refer to table 1 for equipment data.

Table 1. Front and Rear Differential.

Manufacturer AM General Manufacturer Dana Corp

Type Hypoid Gears Type Hypoid Gears

Model Basic, A1 Model A1, A2, ECV

Oil Capacity 2 qt (1.0 L) Oil Capacity 2 qt (1.0 L)

EQUIPMENT DATA PLATE

The equipment data plate is displayed on the differential and shows the manufacturer, model, and serial number. If the data plate is damaged or illegible, it must be replaced. Transfer pertinent data from the damaged data plate to a new data plate.

REBUILD DATA PLATE

After the differential has been rebuilt, tested, and documented to be serviceable, a rebuild data plate is attached on flat surface above or below vent line hole. The rebuild data plate must show, at a minimum, rebuild facility and date of repair.

END OF WORK PACKAGE

Figure 1. Differential.

OLD CONFIGURATION NEW CONFIGURATION

INPUT FLANGE INPUT FLANGE

DIFFERENTIAL

HOUSING

DIFFERENTIAL

HOUSING

DIFFERENTIAL

COVER

OUTPUT SHAFT

DIFFERENTIAL

COVER W/ COOLER

OUTPUT

FLANGE

NMWR 9-2520-585 0002

0002-1/2 blank

CHAPTER 2

MAINTENANCE INSTRUCTIONS

FOR

DIFFERENTIAL, FRONT AND REAR

HMMWV FOV

NSN 2520-01-291-2975, P/N 12338415-3

NSN 2520-01-358-3160, P/N 12342615

NSN 2520-01-416-5217, P/N RCSK17305

NSN 2520-01-498-9104, P/N 12469309

FRONT AND REAR DIFFERENTIALS DISASSEMBLY

INITIAL SETUP:

Tools and Special Tools General mechanic’s tool kit: automotive

(WP 0018, Item 1)

Differential housing spreader (WP 0018, Item 2)

Rear pinion bearing cup remover (WP 0018, Item 4)

Front pinion bearing cup remover (WP 0018, Item 6)

Tools and Special Tools - Continued

Driver handle (WP 0018, Item 10)

Axle holding fixture adapters (WP 0018, Item 12)

Dial indicator (WP 0018, Item 13)

NOTE

• Work area should be clean, well ventilated, and free from blowing dirt and dust.

• Refer to axle differential housing identification part number located on housing before ordering any replacement parts.

DISASSEMBLY

1. Loosen locknut (Figure 1, Item 2) on output shaft assembly (Figure 1, Item 1).

Figure 1. Output Shaft/Differential Assembly.

NMWR 9-2520-585 0003

0003-1

DISASSEMBLY - CONTINUED

2. Remove locknut (Figure 2, Item 5), O-ring seal (Figure 2, Item 4), output flange (Figure 2, Item 3), and output shaft seal (Figure 2, Item 1) from output shaft (Figure 2, Item 1). Discard O-ring seals (Figure 2, Item 4), output shaft seal (Figure 2, Item 2), and locknut (Figure 2, Item 5).

3. Using slide hammer, remove output shaft assembly (Figure 3, Item 2) from differential housing (Figure 3, Item 1).

4. Repeat steps 1 through 3 for opposite side.

Figure 2. Output Shaft/Differential Assembly.

3 4 5

Figure 3. Output Shaft/Differential Assembly.

0003-2

5. Install axle holding fixture adapters (Figure 4) on differential housing (Figure 4, Item 3) with four capscrews (Figure 4, Item 4). Place differential housing (Figure 4, Item 3) in holding stand.

6. Position differential housing (Figure 4, Item 3) so differential cover (Figure 4, Item 1) faces up. Remove 12 capscrews (Figure 4, Item 2) and differential cover (Figure 4, Item 1) from differential housing (Figure 4, Item 3).

Figure 4. Differential Cover.

AXLE HOLDING

FIXTURE ADAPTER

AXLE HOLDING

FIXTURE ADAPTER

0003-3

CAUTION

• Bearing caps must be marked. Failure to comply may result in damage to equipment.

• Bearing caps and differential housing are a machine matched set.

Bearing caps must be reinstalled into the original differential housing. Failure to comply may result in damage to equipment.

NOTE

• Bearing caps might be marked by manufacturer.

• Mark each bearing cap left and right, top or bottom. Example: LT and RT or LB and RB. This is an example. Use any method as long as the bearing caps can be reinstalled properly.

7. Mark bearing caps (Figure 5, Item 1) if not already marked by the OEM in order for bearing caps (Figure 5, Item 1) to be reinstalled in the same position as they were removed.

8. Remove four capscrews (Figure 5, Item 2) and two bearing caps (Figure 5, Item 1).

Figure 5. Bearing Caps Marking.

0003-4

9. Install differential housing spreader (Figure 6) into holes in axle holding fixture adapters (Figure 6), and install dial indicator (Figure 6) to read from each end of differential housing (Figure 6, Item 1). Dial indicator (Figure 6) must have preload setting of 0.020 in. (0.5 mm).

CAUTION

Do not over tighten differential housing spreader. Failure to comply may result in damage to equipment.

10. Spread differential housing (Figure 6, Item 2) 0.020 in. (0.50 mm) and remove dial indicator (Figure 6).

Figure 6. Differential Housing Spreader.

AXLE HOLDING

FIXTURE ADAPTER

DIAL

INDICATOR

DIFFERENTIAL

HOUSING SPREADER

AXLE HOLDING

FIXTURE ADAPTER

0003-5

NOTE

Tag bearing shims for assembly.

11. Remove differential gear unit (Figure 7, Item 1), two bearing cups (Figure 7, Item 2), and shims (Figure 7, Item 3) from differential housing (Figure 7, Item 4). Discard bearing cups (Figure 7, Item 2).

12. Relieve pressure on differential housing spreader (Figure 7) and remove from differential housing (Figure 7, Item 4).

Figure 7. Differential Case.

DIFFERENTIAL

HOUSING SPREADER

0003-6

13. Rotate differential housing (Figure 8, Item 1) 90°.

14. Remove pinion locknut (Figure 8, Item 5) securing pinion yoke (Figure 8, Item 4) to pinion gear (Figure 8, Item 6).

15. Remove pinion yoke (Figure 8, Item 4) from pinion gear (Figure 8, Item 6).

16. Re-install pinion locknut (Figure 8, Item 5) hand tight.

17. Drive pinion gear (Figure 8, Item 6) from front pinion bearing (Figure 8, Item 2).

18. Remove pinion locknut (Figure 8, Item 5) and discard pinion locknut (Figure 8, Item 5).

19. Remove pinion gear (Figure 8, Item 6) and collapsible spacer (Figure 8, Item 7) from differential housing (Figure 8, Item 1). Discard collapsible spacer (Figure 8, Item 7).

20. Remove pinion seal (Figure 8, Item 3) and front pinion bearing (Figure 8, Item 2) from differential housing (Figure 8, Item 1). Discard pinion seal (Figure 8, Item 3) and front pinion bearing (Figure 8, Item 2).

Figure 8. Pinion Assembly.

0003-7

21. Using driver handle (Figure 9) and rear pinion bearing cup remover (Figure 9), remove rear pinion bearing cup (Figure 9, Item 3) and pinion depth shim (Figure 9, Item 4) from differential housing (Figure 9, Item 1). Discard rear pinion bearing cup (Figure 9, Item 3).

22. Rotate differential housing (Figure 9, Item 1) 180°. Using driver handle (Figure 9) and front pinion bearing cup remover (Figure 9), remove front pinion bearing cup (Figure 9, Item 2) from differential housing (Figure 9, Item 1). Discard front pinion bearing cup (Figure 9, Item 2).

Figure 9. Bearing Cup Installation.

DRIVER

HANDLE

DRIVER

HANDLE

REAR PINION

BEARING CUP

REMOVER

FRONT PINION

BEARING CUP

REMOVER

1 1

0003-8

Do not chisel or wedge ring gear from differential case. Failure to comply may result in damage to equipment.

23. Remove eight capscrews (Figure 10, Item 2) and ring gear (Figure 10, Item 3) from differential case (Figure 10, Item 1).

24. Use press to remove two differential side bearings (Figure 11, Item 2) from differential gear unit (Figure 11, Item 1). Discard differential side bearings (Figure 11, Item 2).

Figure 10. Ring Gear.

Figure 11. Differential Side Bearings.

0003-9

25. Remove rear pinion bearing (Figure 12, Item 1) from pinion gear (Figure 12, Item 2). Discard rear pinion bearing (Figure 12, Item 1).

26. Remove bearing (Figure 12, Item 4) from output shaft (Figure 12, Item 3). Discard bearing (Figure 12, Item 4).

27. Repeat step 26 for opposite side.

END OF TASK

END OF WORK PACKAGE

Figure 12. Rear Pinion Bearing.

0003-10

FRONT AND REAR DIFFERENTIALS CLEANING AND INSPECTION

INITIAL SETUP:

Materials/Parts Anti-seize compound (WP 0017, Item 2)

Cloth, abrasive (WP 0017, Item 4)

Cloth, cleaning (WP 0017, Item 5)

Degreasing solvent (WP 0017, Item 6)

References

TM 9-2320-387-24

ASTM E-1444-05

CLEANING

1. General Instructions. Cleaning procedures will be the same for the majority of parts and components which make up the vehicle subassemblies. Procedures for cleaning will be done in accordance with best commercial and/or local practices. Parts and/or components that require special or specific cleaning procedures will be addressed within this WP. General cleaning procedures are detailed in Steps 2 through 6.

2. The Importance of Cleaning. Great care and effort are required in all cleaning operations. The presence of dirt and foreign material is a constant threat to satisfactory vehicle operation and maintenance. The following will apply to all cleaning operations:

a. Hands must be kept free of any accumulation of grease, which can collect dust and grit.

b. Clean all parts before inspection, after repair, and before assembly.

c. After cleaning, all parts must be covered or wrapped in plastic or paper to protect them from dust and/or dirt.

3. Disassembled Parts Cleaning. Place all disassembled parts in wire baskets for cleaning.

a. Dry and cover all cleaned parts.

b. Place on or in “racks” and hold for inspection or repair.

c. All parts subject to rusting must be lightly coated with oil and wrapped.

d. Keep all related parts and components together. Do not mix parts.

WARNING

Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shields gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

4. Castings

a. Clean inner and outer surfaces of castings and all areas subject to grease and oil with degreasing solvents.

b. Use stiff brush to remove sludge and gum deposits.

c. Use compressed air to blow out all tapped capscrew holes and dry castings after cleaning.

5. Oil Passages. Particular attention must be given to all oil passages in castings and machines parts. Oil passages must be clean and free of any obstructions.

a. Clean passages with wire probes to break up any sludge or gum deposits.

b. Wash passages by flushing with degreasing solvents.

c. Dry passages with compressed air.

NMWR 9-2520-585 0004

0004-1

CLEANING - CONTINUED

Do not allow degreasing solvents to come in contact with seals, cables, or flexible hoses. These cleaners cause leather, rubber, and synthetic materials to dry out, rot, and lose pliability making them unserviceable.

6. Nonmetallic parts. Clean hoses and other nonmetallic parts with soap and water.

END OF TASK

GENERAL INSPECTION

1. General Instructions. Procedures for inspections will be the same for many parts and components which make up the vehicle subassemblies. General procedures are detailed in Steps 2 through 11. Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified inspection equipment for inspection where cracks and other damage cannot be seen. Use caution in all phases of inspection. Repair or replace unserviceable components.

2. Castings.

a. Inspect all ferrous and nonferrous castings for cracks. See ASTM E-1444-05 (Inspection, Penetrant Methods). Check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace cracked castings.

b. Inspect machined surfaces for nicks, burrs, and raised metal. Mark damaged areas for repair or replacement.

c. Inspect all pipe plug openings and capscrew openings for damage and stripped threads. Replace if damaged. If stripped threads cannot be repaired, replace components.

d. Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or surface place. Inspect mating flanges for discolorations which may indicate leakage. Replace if warped.

e. Check all castings for conformance to applicable repair standards.

3. Machined Parts.

a. Check machined parts for cracks, distortion, and damage.

b. Check all surfaces for nicks, burrs, and raised metal.

c. Replace studs, bolts, capscrews, and nuts if bent, loose, stretched, or threads are damaged.

4. Gears.

NOTE

When gear teeth wear limits are not established, good judgment is required to determine if gear replacement is necessary.

a. Inspect all gears for cracks and missing teeth. Replace if cracked or teeth are missing.

b. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.

c. Inspect splines for wear, burrs, and galled or pitted surfaces.

d. Check keyway slots for wear and/or damage.

0004-2

GENERAL INSPECTION - CONTINUED

5. Geared Units.

NOTE

Inspection procedure for differentials is converted to the new Differential Gear Unit, NSN 2520-01-357-5056.

a. Remove differential gear unit from the differential housing.

b. Clean gear unit.

c. Insert axle shafts into gear unit and manually turn axle shafts clockwise and counterclockwise to get a full 360° turn on the gears while visually inspecting the center gear and all three sets of worm/spur gears for chipped/broken gear teeth, scarring, discoloration, and sharp/knifed edges on the worm gears. Minor scarring and discoloration of gears is allowable. Replace gear unit if gears are broken or knifed edged. A single chipped spur gear per set is allowable. Replace differential gear unit if more than a single chipped spur gear per set is found.

d. While turning the shafts, gears must turn freely and smoothly. Evidence of binding is not allowed.

e. Measure end play (thrust) of center gear with feeler gauges between the thrust washer and center gear. Measurement is taken at the end opposite side of the ring gear mounting. Turn axle shafts to ensure center gear is tight against thrust washers at ring gear end before taking reading. If measurement is 0.015 in. (+ 0.000 in., -0.003 in.), differential gear unit must be replaced.

f. Scoring around the outside of the gear unit housing from the pinion gear is evidence of pinion gear bearing failure or loss of pre-load on pinion shaft. If gouging is deeper than 0.0625 in. (1/16 in.), the gear unit must be replaced. Slight “metal peen over” can be dressed up with a file ensuring that the filings do not get into the gear unit. Any “metal peen over” in the area of the spur/worm gears must not interfere with the rotation of the gears. (The 1/16 in. is an approximate measurement. The maintainer shall use their judgment and expertise as to how wide scoring is and if it goes all the way around gear housing.)

6. Oil Seals. Oil seals are mandatory replacement items.

7. Casting Plugs. Inspect for leakage. Replace plugs when leakage is present.

8. Springs. Inspect for damaged, distorted, and collapsed coils.

9. Snap Rings, Retaining Rings, and Washers. Many of these parts are mandatory replacement items.

Inspect all others for obvious damage.

0004-3

10. Differential Housing. Inspect differential housing (Figure 1, Item 1) and all threaded holes for damage.

Repair any damaged threads with thread repair inserts. Replace differential if differential housing (Figure 1, Item 1) is damaged.

NOTE

Ring and pinion gears must be replaced as matched set.

11. Splines and Gear Teeth. Inspect splines and gear teeth on pinion gear (Figure 2, Item 1) and ring gear (Figure 2, Item 2) for damaged or broken teeth and wear. Replace both pinion gear (Figure 2, Item 1) and ring gear (Figure 2, Item 2) if damaged or worn.

Figure 1. Differential Housing.

Figure 2. Gears.

0004-4

12. Splines and Sealing Surfaces. Inspect splines and sealing surfaces on pinion yoke (Figure 3, Item 1) and output shafts (Figure 3, Item 3) for damage. Replace if damaged.

NOTE

• If rear pinion yoke is being replaced, a new slinger must be installed on new pinion yoke.

• Push rear pinion yoke into slinger until slinger is seated against rear shoulder of yoke.

13. Differential Gear Unit. Inspect differential gear unit (Figure 3, Item 2) for damage. Replace if damaged.

END OF TASK

Figure 3. Differential Components.

1 2 3

0004-5

EQUIPMENT TESTS

TEST EQUIPMENT LEAK CHECK

1. Connect regulating valve assembly (Figure 4, Item 1) to draincock adapter assembly (Figure 4, Item 3) with coupling (Figure 4, Item 2).

WARNING

Differential oil cooler assembly is under high pressure. Release air from assembly by using the air draincock before disconnecting any air lines. Air is under pressure and creates danger to eyes. Wear safety goggles to prevent serious personal injury. Seek medical attention in the event of an injury.

NOTE

Submerge test equipment assembly in water after pressurization to check for leaks.

2. Connect regulating valve assembly (Figure 4, Item 1) to shop air source. Open air inlet valve on regulator and pressurize test assembly at 100 psi for one minute. If leaks are found, tighten or replace components as required.

3. Disconnect regulating valve assembly (Figure 4, Item 1) and draincock adapter assembly (Figure 4, Item 3) from coupling (Figure 4, Item 2).

Figure 4. Test Equipment Leak Check.

0004-6

TEST EQUIPMENT INSTALLATION

1. Connect regulating valve assembly (Figure 5, Item 1) to inlet side (Figure 5, Item 2) of differential oil cooler cover assembly (Figure 5, Item 3).

2. Connect draincock adapter assembly (Figure 5, Item 5) to outlet side (Figure 5, Item 4) of differential oil cooler assembly (Figure 5, Item 3).

Figure 5. Test Equipment Installation.

NMWR 9-2520-585 0004

0004-7 chad.l.bergemann Text Box 4.

chad.l.bergemann Text Box 5.

chad.l.bergemann Line

DIFFERENTIAL OIL COOLER COVER ASSEMBLY TEST

WARNING

Differential oil cooler assembly is under high pressure. Release air from assembly by the air draincock before disconnecting any air lines. Air is under pressure using and creates danger to eyes. Wear safety goggles to prevent serious personal injury. Seek medical attention in the event of an injury.

NOTE

Submerge test equipment assembly in water after pressurization to check for leaks.

1. Connect regulating valve assembly to shop air source. Slowly open air inlet valve on regulator and pressurize differential oil cooler assembly at 100 psi for one minute. If leaks are found, discard differential oil cooler cover assembly.

2. Inspect differential oil cover assembly for cracks or any other noticeable defects. If defects are found, discard differential oil cooler cover assembly.

3. Disconnect shop air from regulating valve assembly and vent air pressure from differential oil cooler assembly by opening draincock.

4. Dry off differential oil cooler cover assembly as needed.

FINAL PREPARATION

1. Remove draincock assembly (Figure 6, Item 5) from outlet side (Figure 6, Item 4) of differential oil cooler cover assembly (Figure 6, Item 3).

2. Remove regulating valve assembly (Figure 6, Item 1) from inlet side (Figure 6, Item 2) of differential oil cooler cover assembly (Figure 6, Item 3).

3. Install differential oil cooler cover assembly on differential, if serviceable. (Refer to TM 9-2320-387-24.)

END OF TASK

Figure 6. Test Equipment Final Preparation.

NMWR 9-2520-585 0004

0004-8 chad.l.bergemann Callout Delete - Already part of Assembly Step 66 chad.l.bergemann Line chad.l.bergemann Text Box 6.

chad.l.bergemann Line chad.l.bergemann Text Box 7.

chad.l.bergemann Text Box 8.

chad.l.bergemann Text Box 9.

chad.l.bergemann Text Box 10.

chad.l.bergemann Line chad.l.bergemann Text Box 11.

GENERAL REPAIR

1. General Instructions. Repair of most parts and components is limited to general procedures outlined in applicable maintenance instructions and the following detailed procedures 2 through 8.

CAUTION

Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of vehicle components.

2. Castings.

a. All cracked castings will be replaced.

b. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and/or scratches by:

1. Using fine mill file

2. Using abrasive cloth dipped in cleaning solvent

3. Lapping across a surface plate

4. Re-machining of machined surface to repair damage, warpage, or unevenness is not permitted.

c. Repair damaged threaded pipe plugs and/or capscrew holes with a thread tap or repair oversize holes with threaded inserts.

3. Bearings. Bearings are mandatory replacement items.

4. Stud(s). Replace all bent and stretched stud(s). Repair minor thread damage with a thread restorer file.

Replace stud(s) having stripped or damaged threads as outlined below:

a. Remove using a stud remover. Back stud(s) out slowly to avoid heat buildup and seizure, which can cause stud(s)to break off.

b. If stud(s) are broken off too short to use a stud remover, use extractor to remove stud(s).

c. Replacement studs have a special coating and must have a small amount of anti-seize compound (NSN 8030-00-059-2761) applied on threads before stud(s) is installed. Install replacement stud(s) slowly to prevent heat buildup, damage to threads, or breaking of studs.

5. Gears.

a. Remove gears using pullers, as required.

b. Use the same methods described in CASTINGS to remove minor nicks, burrs, or scratches on gear teeth.

c. If keyways are worn or enlarged, replace gear.

6. Bushings and Bushing Type Bearings. When bushings and bushing type bearings seize to a shaft and spin in the bore, the associated part must also be inspected and replaced, as required.

7. Oil Seals.

a. Remove oil seals, being careful not to damage casting or adapter bore.

b. Always install new seal in bore using proper seal replacing tool.

8. Locking Threads. When using thread sealing compound:

a. Apply a liberal amount to both male and female threads on…