6.
Verify bearing preload and pinion gear shaft (8) rota-
tion as follows:
A. Install coupler flange (19), washer (17), and lock
nut (18) to the shaft of the pinion gear. Torque lock
nut from 75 to 90 ft–lb (102 to 122 N–m).
B. The torque required to rotate the shaft of the pin-
ion gear should be from 7 to 12 in–lb (8 to 14 kg–cm)
(Fig. 39).
C. If the torque required to rotate the shaft of the pin-
ion gear is more than specified in step B, remove lock
nut, washer, coupler flange, bearing cone (22), and
shim (21) from the shaft of the pinion gear. Increase
shim thickness to decrease bearing preload.
Figure 39
D. If the torque required to rotate the pinion gear
shaft is less than specified in step B, remove lock nut,
washer, coupler flange, bearing cone (22), and shim
(21)
from the pinion gear shaft. Decrease shim thick-
ness to increase bearing preload.
E. Install shim, bearing cone, coupler flange, wash-
er, and lock nut to the pinion gear shaft. Torque lock
nut from 75 to 90 ft–lb (102 to 122 N–m).
F. The torque required to rotate the pinion gear shaft
should be from 7 to 12 in–lb (8 to 14 kg–cm). If the
torque to rotate the pinion gear shaft does not meet
specification, repeat steps C or D and E as neces-
sary.
Figure 40
SPLINES
G. If the torque required to rotate the shaft of the pin-
ion gear shaft is as specified in step B or F, remove
lock nut, washer, coupler flange, bearing cone (22)
from the shaft of the pinion gear. Press new oil seal
(20)
into the carrier assembly (15) (Fig. 40).
H. Apply No. 2 Permatex sealant or equivalent to the
splines of the pinion gear. Make sure not to get
sealant on the oil seal (20) (Fig. 41).
Figure 41
I. Install flange coupler, washer, and lock nut back
onto the pinion gear. Torque lock nut from 75 to 90
ft–lb (102 to 122 N–m).
7.
Install thrust washers (7) to pinion gear shafts (6),
and thrust washers (4) to side bevel gears (5) (Fig. 42).
A. Place gears and washers into the differential
case (27).
B. Rotate both sets of gears simultaneously until the
pinion shaft (25) can be inserted through the differ-
ential case, thrust washers, and pinion gear shafts.
C. Install pinion shaft into the differential case and
pinion gear shafts. Secure shaft with roll pin (28).
Figure 42
Workman 4000 Series
Page 10 – 25
Front Wheel Drive (4WD)
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