David Brown 885 Tractor Service & Repair Manual

dl CASE BROWN) MODELS: 885·885N·995-1210·1212·141o.1412 INDEX (By Starting Paragraph) BELT PULLEY ....................... • ......... BRAKES, WHEEL ............................ .. CLUTCH: Adjustment., ..... " ...... ". 0' •••••••••••••••• Remove & Reinstall . ...... > , •• , •••••••••••••••• Overhaul . .... , . > ••••••• > •••• < •••••••••••••••• COOLING SYSTEM: Radiator ............... , ..... ,., ..... , ... , ... . Thermostat . ..... " ...... , .................... . Water Pump . ............ " . > ••••••••••••••••• DIESEL FUEL SYSTEM: Bleeding Fuel System ......................... . Filters . ........... , ... , ., .. 0 •••••••••••••••••• Injection Pump ............................... . Injector Nozzles. .. ., .. 0 , • ' ••• , • , •••••••••••• Troubleshooting ............................. . DIFFERENTIAL: Adjust ...................................... . Lock ........................................ . Overhaul. ................................... . Remove & Reinstall. > ••••• , " •••• , •••••••••••••• ELECTRICAL SYSTEM: Alternator . .... , ...... , ... , , .... , ............ . Starting Motor .......................... . ENGINE: Assemhly. R&R ......................... . Cam Followers . .. " ........ ", .... " ....... , ..... . Camshaft .................................... . Connecting Rod Bearings . ..................... . Crankshaft & Bearings ........................ . Crankshaft Oil Seals ...................... '" .. Cylinder Head ................................ . Cylinders .................................... . Flywheel. R&R ............................... . Main Bearings ................................ . Oil Pan ...................................... . Oil Pump .................................... . Piatons & Rings .............................. . Piston & Rod Removal. ....................... . Piston Pins . ....... _ . . .. . ... _ ............... . Rocker Arms ................................. . Timing Gear Cover ..... , ....... , ............. . Timing Gears ......................... " ... " .. . Turbocharger . ............................ " .. . Valve Adjustment ............................ . Valve. Guides & Seats ........................ . Valve Springs ................................ . 885 225 215 143 146 150 128 130 131 103 102 110 120 94 201 205 204 200 132 140 57 76 77 82 85 87 63 84 93 85 92 90 83 80 81 65 71 73 66 66 70 995 225 215 144 146 150 128 130 131 104 102 113 120 94 201 205 204 200 132 140 59 76 78 82 86 87 63 84 93 86 92 90 63 80 81 65 72 74 67 68 70 1210, 1212 225 216 145 147 152.153 129 130 131 105 102 115 120 94 201.202 205 204 200 132 140 61 76 78 82 86 87 63 84 93 86 92 90 83 80 81 65 72 74 67 68 70 1410, 1412 225 216 145 148 153 129 130 131 105 102 115 120 94 201.202 205 204 200 132 140 61 76 78 82 86 87 63 84 93 86 92 90 83 80 81 65 72 74 93A 67 68 70

INDEX (Cont.) FINAL DRIVE ASSEMBLY: Assembly, R&R .............. . . . . . .. , ......... 207 207 207 207 Axle. Gear, Bearings & Seal .................... 208 208 209 209 FRONT AXLE (Four Wheel Drive): Axle Assembly ................................ 10 Differential ................................... 21 Drive Shaft ................................... 29 Final Drive . .................... , ... , ......... 12 Tie-Rod & Toe·In .............................. 11 Transfer Gearbox . .... , ... , .... , ............. ' 27 FRONT AXLE (Two Wheel Drive): Axle Main Member ............................ 7 6,7 7 7 Front Support ................................. 8 9 9 9 Pivot Pins .. , ................. , ... , .......... , 7 6,7 7 7 Steering Spindles . .. , .......................... 3 3 3 3 Tie Rods & Toe-In .................... ........ , 5 5 5 5 HYDRAULIC LIFT SYSTEM: Adjustments .................................. 262,276 262,276 262,276 262,276 Control Valve ................................. 274 274 274 274 Fluid & Filters ................................ 255,282 255,282 255,283 255,283 Lift Cylinder .................................. 279 279 279 279 Lift Cylinder Rockshaft ........................ 280 280 280 280 Linkage, Overhaul ............................. 277 277 277 277 Operating Principles . ...... , ........ , ........ , . 241 241 241 241 Pump ........................................ 270 270 273 273 Relief Pressure . . , .................... < ••••••••• 257 257 257 257 Remote Control Valves . ........................ 284 284 284 284 Sensing Unit .................................. 281 281 281 281 Three-way Valve .............................. 284 284 284 284 Troubleshooting ............................... 256 256 256 256 POWER STEERING: Bleed System ................................. 35 35 34,35 35 Control Valve . ..... , ............. , .. 0 ••••• , •• , 52 52 52 52 Power Cylinder . .............................. 45 45 45,46.47 47 Pump ........................................ 37 39 39 39 System Pressure . ................ , . , ...... " ... 36 36 36 36 POWER TAKE-OFF: Overhaul ..................................... 282 232 233,284 283,234,285 Remove & Reinstall . ........................... 230 230 230 280 Shaft Oil Seal ................................. 231 231 231 231 REAR AXLE: Axle Housing Oil Seals ......................... 203 208 209 209 Housing, R&R ................................. 207 207 207 207 Spur Pinion, R&R ............. 0 ••••••••••••••• 210 210 210 210 STEERING GEAR: Overhaul . .............................. , ..... 32 32 32 Remove & Reinstall. ........................... 30 30 31 TRANSMISSION: Assembly, R&R ............................... 161 161 162,183 162,163 Overhaul ..................................... 166 166 170,175 170,175 Shift Levers & Forks .......................... 157 157 157 157 Transmission Cover. R&R .. .................... 158 159 160 160 Checks and Adjustments ....................... 190 190 3

CONDENSED SERVICE DATA GENERAL Engine Make .................................. .. Engine Model. ................................. . No. of Cylinders .......................... . Bore, Inches ................................... . Stroke. Inches .. ... , ............................ . Displacement. Cubic Inches . ..................... . Compression Ratio . ................. , ..... , . , ... . Pistons Removed From: . . . . . . . . . . . . . .. . ........ . Cylinder Sleeves ............................... . Main Bearings, No. of . .......................... . Generator & Starter Make . ......... , ........... . Forward Speeds, No. of ......................... . Battery Terminal Grounded. , ............... , ... , TUNE-UP Firing Order ................................... . Valve Tappet Gap, Cold: Intake, Inch ................................. .. Exhaust, Inch ......... ' ...................... . Valve Face & Seat Angle ....................... .. Injection Timing, See Paragraph ................. . Engine Low Idle RPM .......................... . Engine High Idle RPM .......................... . Max. Full Load RPM ........................... . Hp at Full Load RPMt ......................... .. SIZES-CAPACITIES·CLEARANCES 885 Own 355011 3 3.939 4.5 164 17:1 Above None 4 Lucas 12 Neg. 1·2-3 0.010 0.010 45· 110 650·700 2350 2200 43.2 995 Own 455071 4 3.939 4.5 219 17:1 Above None 3 Lucas 12 Neg. 1-2·4-3 0.010 0.010 45· 113 650·700 2350·2450 2200 58.77 1210, 1212 Own 455031 4 3.939 4.5 219 17:1 Above None 3 Lucas 12 Neg. 1·2·4·3 0.010 0.010 45· 115 650·700 2450 2300 65.98 (65.38*) 1410, 1412 Own 455011 4 3.939 4.5 219 16:1 Above None 3 Lucas 12 Neg. 1·2·4·3 0.010 0.010 45· 115 650·700 2450 2300 80.88 (80.61'*) (All dimensions are in inches unless otherwise specified.) Crankshaft Main Journal Dia ................... ... ------2.4990·2.4995 ------ Crankpin Journal Diameter ........... " . . ... . .. . . 2.3730·2.3735 ----- Camshaft Journal Dia., Front ........... .......... 2.3725· ---1.870·1.872-- No.2 Journal Dia . ..... , ........ , .... , ...... . No.3 Journal Dia ............................... . No.4 Journal Dia ............................... . No. 5 Journal Dia .. .... , ....................... _ , No.6 Journal Dia .. ... _ ................. _ Piston Pin Diameter .......... ... ' . , ....... , . _ .. . Cylinder Bore Diameter .. ....................... . Piston Skirt Diameter _ ...................... . Valve Stem Diameter . ................. , ........ . Main Bearings Running Clearance . ...... , .. . Rod Bearings Running Clearance . ................ , Crankshaft End Play ............................ . Camshaft End Play ............................ .. Cooling System-Quarts . ......................... . Crankcase-Quarts (With Filter) .................. . Front Differential (FWD)·Pints .................. . Front Hubs (FWD)·Pints .... '" ......... " ...... . Transmission-Quarts (Includes Differential & Hydraulic System) ............................ . Final Drive, Each-Pints . ........................ . Steering Gear· Pints ....................... . tNebraska Test '1212 Model **1412 Model 2.3735 1.8707· --1.825-1.827-- 1.8720 1.8409 1.8422 1.7940 1.7954 1.7475- 1.7488 --1.810·1.811-- --1.810·1.811-- --1.763·1.765-- --1.747·1.749-- ------1.250 -----3.93883.9396 ----- -----:3.9315-3.9323 ----- -----10.3722-0.3732 ----- -----0.002·0.004----- =====0.002-0.004----- 0.002·0.010 ----- -- 0.010·0.020-- 0.002· 0.006 9 6 1 1z 46,43 4'1< 6 15 8

885-995-1210-1212-1410-1412 Paragraphs 1-4 FRONT AXLE (TWO WHEEL DRIVE) FRONT WHEEL BEARINGS All Models Except 88SN 1. A typical front wheel spindle, wheel hub and bearing assembly is shown in Fig. 1 or 4. The tapered inner and outer roller bearings are the same size on some models. however if bearings are to be reused they should be reinstalled with mating bearing cones and cups togeth- er. Note that lip of oil seal is installed away from inner bearing. It is recom- mended that bearings be lubricated with a pressure gun until grease is forced out past seal lip after each 60 hours of operation. When adjusting wheel bearings. tighten nut to provide 0.003 inch end play to 0.002 inch preload and install cotter pin. Model8S5N 2. The Model 885N front wheel spindle. wheel hub and bearing assem- bly shown in Fig. 2 is similar to other models except that bearing adjustment is controlled by shims (5). Vary shims as required to provide 0.003 inch end play to 0.002 inch preload and secore heads of cap screws with tabs of leek plate (3). Shims (5) are available in thicknesses of 0.005, 0.010 and 0.030 inch. SPINDLES All Models 3. R&R SPINDLES. To remove spindle. support front of tractor and remove wheel. Remove cap screw and washer which retains steering arm and remove steering arm from spindle. NOTE: If steering arm Is tight on spindle, loosen cap screw about two or three turns and rap head of cap screw sharply to loosen steering arm from spindle. Withdraw spindle and remove upper "0" ring and thrust washer or thrust bearing and lower "0" ring. Reinm stall by reversing removal procedure and tighten steering arm retaining cap screw to 120 ft.-Ibs. torque. 4. SPINDLE BUSIIINGS. With spin- dle removed, spindle bushings can be removed from axle extension using a suitable drift punch. New bushings are presized and should not require ream- ing if carefully installed. Outer ends of bushings should be flush with axle Fig. 1-Exploded ,"lew of front axlll wheel spIn dis. hub and bearing assembl, typlca' of those used on Models 885 and 995. Mod· e' ,85H 'S shown In Fig. 2. Oil sea' Is installed with lip away from Inner blte,- ing. 1. Hub cap 2. Gasket 3. Nut 4. Washer 5. Hub 6. Bearingll 7. Seal 8. Sleeve 9. Dirt excluder i~: ~h:~ washer 12. Tie·rod end 13. Tie·rod inner tube 14. Tie·rod outer tube 15. Bushing 16. Axle extension, L.R. 17. "0" ring 18. Steering ann, L.H. 19. Washer 20. ~ screw 21. "'0' ring 22. Thrust washer 23. Bushin~. front ~: ~v:!S!d insert 26. Busbing, rear Zl. Drag link 28. Steering arm, R.R. 29. Axle enension. R.H. 30. Main member 31. "0" ring Fig. 2-Exploded vIew of Model ,aSH 'ront axle, WhH' spindle, hub end bea"ng assembly. Note shims (5) used to adjust beallngs. 1. Hub cap 2. Gasket 3. Lock plate 4. Washer. special 5. Shima (.005, .010, .030) 6. Bearings 7. Hub 8. Sea] 9. Seal housing 10. Spindle 11. Thrust washer 12. Tie-rod end 13. Tie-rod inner tube 14. Tie·rod outer tube 15. Bushing 16. Axle extension, L.R. 17. "0" ring 18. Steering arm, LB. 19. Washer 20. Cap screw 21. Bushing, front 22. "'0" ring 23. Main member 24. Pivot pin 25. Thrust washer 26. ''0'' ring 27. Bushing, rear 28. Drag link 29. Steering arm, R.H. I I 2122 I J.J 23 24 I 25 I I 20~1~ 19 18 _-"' L-:-=- ..J 30 17 - ~- , 21 29 I I I 16 15 I ~' I I ~4 =:~ I I c.--- , ~ I I I I ~~ 13 IF ,. ---"' c.--- 6 789 11 5 31 1 2 3 ~~~::::'J-IO ~~l~~. ~. 4 6 20 19-"'''/ 18 I . " . 25 26 30 I (:-;0 00 ' 27 \ ::ooro~~ IV? l~J 14 I r-"" 1'3 I 12 _-1 I _ , l---- 8 9 11 7 1 2 3 <lP 4 56 5

Paragraphs 5-6 extension. Bushings are alike for 8 series and 9 series (with 52·76 inch width axle) tractors but upper bushing has a smaller I.D. for 9 series (with 56-80 inch width axle), 12 series and 14 series tractors. TIE-RODS AND TOE-IN All Models 5. Toe-in of front wheels should be l/16-l/S-inch and can be adjusted by lengthening or shortening the tie-rod. Adjust tie-rod ends an equal amount. Tie-rod ends are available as a unit only. AXLE MAIN MEMBER AND PIVOT PIN All Models 6. On early 995 (prior ser. no. 934315) \.ractors it is necessary to split tractor between front support and main frame using the following procedure: Remove hood and drain cooling system. Disconnect radiator hoses. battery cable and air cleaner hose at rear side of radiator. Disconnect drag link (manual steering) or steering ram (power steering) from steering arm. Support traetor under main frame and attach a hoist to Iront unit. Unbolt Iront support Irom main frame and roll assembly away from tractor. Loosen the pivot pin retaining cap screw about five turns, rap on head of cap screw to dislodge threaded insert, then remove cap screw and threaded insert. Attach a slide hammer, pull pivot pin rearward from front support and front axle. then raise front support until it clears axle assembly. Remove the thrust washers and sealing "0" rings. The two rear bushings (B-Fig. 5) may be removed with suitable driver. To remove the two front bushings from blind hole. use a cape chisel and pliers. Drive new forward front bushing into blind hole until it bottoms or is forward of lubrication hole. then drive second front bushing in flush with support casting. Drive rear bushings into sup· port from each side until bushings are flush with support casting. Bushings are pre·sized and should not require reaming if carefully installed. Be sure pivot pin is a free fit in bushings before reinstalling front axle to front support. The axle front to rear float in front support should be 0.002-0.014 inch. Renew pivot thrust washers if front to rear float is excessive. When rejoining front support to main frame, tighten bolts to 45 ft.-lbs. torque. 6 Fig. 3-Exploded ~,.w of front Ix'e 8ssemb'y used on Models 1210. 1212, 1410 and 1412 equipped with transverse mounted powe, Iteerlng cylinder. Mqd.'9 1210 and 1212 with manua' st •• rlng 01 .,de mounted powel steelInG cylinder ha~e alde• • Imllar 10 that shown In FIG. 1. 1. Bushing, lower 2. Axle extension, RH. a. "0" ring 4.. Bushing, upper 6. Plastic plug 6. Tie-rod end 7. Dirt excluder 8. Steering ann 9. Tie-.rod outer tube 10. Pivot pin 11. Pivot link 12. Bushing 13. uO" ring 14.. Washer 15. Nut 16. "0" ~ 17. Pivot pm 18. ~ring pin 19. Fork 20. Tie-rod inner tube 21. Main member 23. Grease tube 24. Bracket 25. Grease fitting 26. Pivot (trunnion) pin 27. Threaded insert 28. Thrust washer 29. "0" ring 30. Bushings 31. Axle extension, LlI. Fig. 4-Exploded ~I._w of Models 1410 and 1412 fronfaxle, wheel spindle, hub and bearing assembly. Sea' (9) #s Insfalled with lip 'acIng awey 110m Inner be.,lng. 1. Hub cap 2. Gasket 3. Nut 4. Washer 5. Bearing 6. Grease fitting 7. Hub 8. Bearing 9. Seal 10. Seal sleeve 11. Dirt excluder 12. Spindle 13. "0" rin 14.. Thrust tearing 15, Thrust washer 16. Bushing 17. Axle extension 18. "0" ring 19. B~hin. 20. Tie-rod end 21. Dirt excluder 22. Steering ann 23. Loeimut 24.. Cap serew 25. Washer 26. Tie-rod inner tube 2:1. Fork 28. Threaded insert 29. Cap serew SO. Grease tube 81. Grease fitting 32. Main member 38. Bushings 34. "0" ring 35. "0" ring 36. Thrust washer 37. Pivot pin as. Main member \//' J I CASE (DAVID BROWN) /' /' ,/ /' /' /' /' /' /' /' /' /' 32 38 /'

885-995-1210-1212-1410-1412 Paragraphs 7-12 7. On alI models except early 995, reo move axle main member as follows: Disconnect drag link, or side mounted steering ram from left steering arm; or on models with transverse steering rams, disconnect steering pipes at rear of axle and place a suitable container under pipe ends. Loosen cap screw retaining pivot pin about five turns. rap head of cap screw to dislodge threaded insert, then remove cap screw and threaded insert. Remove expansion plug from front support casting and remove pivot pin with slide hammer threaded into front end of pivot pin. Remove old bushings and install new bushings using a suitable driver. New bushings are pre-sized and should not require reaming if carefully installed. Bushings in some models are different lengths and bushing location should be noted during removal and installation. Renew sealing "0" rings. thrust wash- ers and expansion plug during reassem- bly. FRONT SUPPORT Models 885, 88SN 8. The front support is an integral part of the main frame casting. To renew the main frame. first remove engine as outlined in paragraph 57. Remove air cleaner and support assem· bly, battery and battery tray. Remove front axle pivot pin as outlined in paragraph 7. then unbolt and remove main frame from transmission housing. When reassembling. tighten main frame to transmission bolts to a torque of 45 ft.-lbs. All Models Except 885, 88SN 9. To renew the front support casting. proceed as outlined in para· graph 6 and also remove radiator. air cleaner, battery and battery tray and, on models so equipped. remove front mounted hydraulic pump and bracket assembly. FRONT AXLE (FOUR WHEEL DRIVE) Model 1210 tractors are available with a front drive axle which is driven from the transmission bevel pinion shaft via a transfer case and a drive shaft. A shifting mechanism in the transfer ease allows connecting or disconnecting power to the front axle as required. Front wheel toe·in on tractors equipped with the front drive axle should be 0 to 3/64 inch. FRONT AXLE ASSEMBLY Model 1210 10. R&R FRONT AXLE. The four wheel drive front axle can be serv.iced without removing it from tractor. However. if removal is required. pro- ceed as follows: Disconnect steering ram from left steering arm and axle housing and secure to main frame. DisConnect drive shaft from flange of differential. Loosen pivot pin retaining cap screw about five turns, rap head of cap screw to dislodge threaded insert (lB-Fig. 6), then remove cap screw and insert. Attach hoist to front of tractor and take weight off tractor. Place a rolling floor jack under front axie to prevent it from tipping and remove pivot pin. Fig.5-Crossa$ectional If/ew showing e typlca' pivot pin Installation. A tapped hole (H) is prodded so pivot pin can be re-- moved with a slide ham- mer. Bolt (14) Is located toward rear of pivot pin on 9, 12 and 14 series trac- tors. Thrust sleeves (18) al'8 no longer used. 18 Raise front of tractor until it clears front axle and roll axle from under tractor. Reinstall front axle by reversing removal procedure. TIE-ROD AND TOE-IN Model 1210 11. Recommended toe-in for front drive axle is zero (0·3/64) inch. Tie·rod has one adjustable end and should be adjusted to maintain the zero inch toe-in. FINAL DRIVE ASSEMBLIES Model 1210 12. The final drives (outer reduction units) for all practical purposes are identical. The primary differences being the left hand carrier (1S-Fig. 7) has the power steering ram attached to it and 13 o - 18 19 H B 20 14 15 20 B B. Bushings 13. Threaded insert 18. Thrust sleeves H. Tapped hole 12. Pivot pin Fill. 6-View at front ax'e housing used on Model 1210 four-wheel drive t,..c~ tors. 1. Bushings 2. "0" ring 3. Thrust washer 4. Pivot pin 5. Grease tube 6. Grease fitting 7. Breather 8. Axle housing 9. Cover plate 10. Oil seal 11. Snap ring ~:~e~l 14. Seal 15. Tie-rod end 14. Retaining bolt 15. Axle main member 14---.. 15 19. ~O" rings 20. "0" rings 7

Paragraphs 13·15 the right hand axle shaft is shorter than the left hand axle shaft. 13. REMOVE AND REINSTALL. To remOVe final drive, jack up affected side of axle, remove wheel and tire and drain housing. Disconnect tie·rod from carrier and if left band unit is involved. also disconnect the power' steering ram from carrier. Remove cover plate (9-Fig. 6). Remove cap screw and lock (21.Fig. 7) and adjusting nut (20), then remove king pin (22) using tapped hole in bottom of king pin. Withdraw final drive, unit from axle housing and take care that axle shaft does not damage bearing (15·Fig. 8) located in axle housing. NOTE: If necessary. s- tool for removal at king pin can I)e fabricated using the dimensions shown in, Fig. 9. The values shown are in millimeters. Also note when using removar tool, removal of king pin will be a three-step operation. Bearing (19-Fig. 7), lower washer (18), "0" ring (17) and seal (16) can now be removed. DO NOT remove upper beariDg (11) unless it is to be renewed or other new !inal drive parts are being insWIed. If necessary, axle hearing (15·Fig. 8) can be pulled from axle housing after removing oil seal (17) and snap ring (16). 14. The final drive assembly is installed by reversing removal proce· dure. however if a new axle housing. final drive housing (carrier), king pin upper bearing or spacer is installed, the mounting dimensions of axle hOlls· ing and final drive honsing must be ehecked and reset, if necessary. to insure that axle halves are in align· ment. During machining of the final drive housing (carrier) and axle housing, plus or minus deviations can occQr and are stamped on final drive carrier and axle housing as shown in Fig. 10. The reference dimension for final drive housing (carrier) is 107.00mm and reference dimension for axle housing is 72.90 mm. Plus deviations are added to reference dimensions and minus devia- tions are subtracted from reference dimensions. If there is no deviation during machining the deviation stamp· ing will be "0" (zero). Also needed to calculate the required thickness of spacer is the overall thickness of king pin upper bearing assembly. Standard thickness of bearing is 25.60 mm but it should he measured as deviations can occur. Refer to the following paragraph for an example to calculate spacer thick- ness. 8 15. Assume the final drive housing (carrier) is stamped with + 0.18 devia- tiOD, the axle housing with - 0.12 deviation and upper bearing measures 25.60 mm. Reference dimension of final drive housing Plus deviation Final drive housing dimension Fig. 7-Exploded view of "nal drIve shatt and reduc· lion housIng,' Final drive shefl gears (7) are right and leff hand. Re'.r to text for Information on spacer (12), 1. Final drive shaft 2. Oil seal S. Shim 4. BelLrin~ aslIy. 5. Snap rmg 7. Gear 8. Tab, washer 9. Nut 10. Bearing assy. 11. Bejl,ring assy. 12. Spacer 13. "0" ring 14. Seal 15. Carrier 16. Seal 17. "0" ring 18. Washer 111. Bearln~-assy. 20. Adjusting nut 21. Lock plate 22. King pin 23. Level plug 24. Magnetic drain plug 25. Breather 26. Housing 21. Plug 28. Plug 29. Wheel stud Fig. a-Right and letl hand axle shari Bss.m~ bliss' Ite Identical except for 0'l8,all length and all parts are avallabl, 'or ser- "le •• Itams 19, 20 end 2f ere fnstalled In axle hous- Ing. Spacer (3) Is available In thlckness.s 01 1.60 mm through 2. 70 mm. 1. Pin 2. Bearing assy. 3. Spacer 4. Shaft and gear 5. Set screw 6. Cross piece 7. Plug 8. Snap ring 9. Bearing 10. Center yoke 11. Axle slWt 12. Split bushing 13. Bearing assy 14. Oil seal 15. Bearin$ 16. Snap nng 17. Oil seal 18. Carrier 19. Level plug 20. Breather 107.00 mm +0.18mm 107.18 mm J I CASE (DAVID BROWN) Reference dimension of Axle housing Minus deviation Axle housing dimension Final drive housing dimension Minus axle housing dimension Minus hearing thickness Equals spacer thickness required 72.90mm ·O.12mm 72.78 mm 107.18 mm . 72.78mm ·25.60 mm 8.80mm g 16 I ~ 17 I ~ 18 1~19 1~20 U t'21

paragraph$ 19-20 ptlor 10 Inslalllng linal drive shalt gear (7). Position final drive shaft with wheel studs down and block under shaft so wheel studs are not touching. Place housing (26). over final drive shaft. Heat.gear (7) to about 100 degrees F,. start gear on. splines of final drive shalt. then press or drive. gear and housing on final drive shaft. Install loekwasher (8) and nut (9) and tighten nut securely. Distance from nut to end of shaft should he the same as that recorded prior to disassembly. ,about 3 mm (l/8'in.) of final drive shaft thread should be, exposed with nut tightened. Retain nut by bending tabs of lock· washer __ into slots in nut and gear~ . Refer to paragraph 20 for informa· tion to join housing to carrier. 19. AXLE SHAFT. To remove axle shaft from carrier, support. carrier and axle -shaft a_nd drive bearing co,:te (l,S-Fig. 8)· into carrier far enough to allow removal of split bushing (12). Use a soft faced hammer and drive axle shaft out of hearing and carrier. Seal (14) and he'l'"ing cup (13) can now be removed from carrier. Outboard bear c ing assembly (2) cannot be removed unless final drive shaft gear (7-Fig.7) has heen removed. Spacer (3) should have been retrieved when housing and Carrier were separa~ NOTE: Tho axle universal Jolnl can be ellsalsembled 8& 'oIlOVlS: Remove snap rings (8·Flg. 8) and pull needle bearings (9). Tip cro •• plocas (6) oul 01 center yoke (10), remove sa' screws (5), then remove pins (1) and sallarate axle halves from cross pieces. It 135 ---- .... , I :- 70------l fl,. 11-A "old'", cl.mp ca_" N """",. loc.,,,·to- p~ .. ltt-.x_" ,moqm.iU dUrI"• ... , .""bl,. Dlm.ii.'on• • r. In mUllm.r.,.. 1,0 Clean and inspect all parts and renew as necessary. Install axle shaft in carrier as follows: Coat outside diameter of seal 114) with sealant and install in carrier (18) with lip toward inside. Gre ... lip of seal. DriVe hearing C1;lP into carrier with taper faCing in, then insert gear end of axle through oil seal and bearing cup. Hold axle in- position and drive bearing cone on axle shaft until the split bushing can be installed with flat side up. Use a soft faced hammer and bump end of axle shaft until axle shaft gear seats on split bushing. NOTE:Ca .. should ba token alter axle -Is Installed to prevent damage to 011 seal (14·Flg. 8) by movement 01 oxle shaft during subsequent assembly. Use of a clamp, shown In Fig. 11. is recommended by the manufacturer and ciampi. Inatollod bslweon carrier and universal Jolnl. Clamp muat bo labrl· caled locally and noto that dimensions are In'mlilimelers. 20. ASSEMBLY. Before joining car- rier (l8'Fig. 8) and housing (26-Fig. 7) the preload for axle shaft must he determined. The axle operates with a 0.25 mm preload and preload is con· trolled by spacer (S-Fig. 8). Spacer is available in thicknesses from 1.60 mm through 2.70 mm in increments of 0.05 mID. Determine correct spacer thi~ess as follows: 1~ Measure from inner race of bear· Fig. 12-Exploded "ltw 01 "ont d,I", dln,,,,,u., and dr'". sh.r, and In Mod., 1210 'our wh"' drl". t,.c>- to". 1. Guard 2. "U" joint repair kit 3. Drive sbaft; 4. Pinion shaft i: ~gBB!lY. 7. Sp,""" 8. Shim 9. Carrier 10. Bearing- usr. 11. A_ 12. LoCkpiate 13. Beorliig US'!. 14. on seal 15. Flange 16. Washer 17. Nut 18. Bevel gear "19. niH. cage 20; Dowel 21. Side gear 22. Loekpin 29. 1'bl'IJst washer 1M. PbUon gear 25. Tbunt washer 26. Busbing '11. Cage end plate J I CASE (DAVID BROWN) ing (2-Fig. 8) to mating face of housing (26·Fig. 7). Fo~ the example. assume it to he 72.5 mID. 2. Measure from inner end of axle shaft gear 14.Fig. 8) to upper face of carrier (18). For the example. assume it to he 70.5 mm. 3. Subtract measurement 2 from measurement 1 which. for the example. is 2.0 mm. 4. Add recommended axle preload of 0.25 mm to difference of measurements 1 and 2 which will give spacer,thick· ness which. for the example. is 2.26 mm. Example: Measurement 1 Minus measurement'2 Equals difference Add preload Required spacer ~ 72.5mm - 70.5 mm 2.0mm +0;25'mm 2.26mm With thickness of spacer determined proceed as follows: Apply sealant to mating surfaces of housing (26-Fig. 7) and carrier (15), then position final drive sboft housing on bench with wheel st\lds down. Lower_ carrier and axle shaft assembly onto fmal drive shaft housing and be sure that axle shaft and final drive sboft enter their bearings (use hoist if necessary). Axle shaft is a push' fit in the outboard bearing and can he seated in the bearing using a hammer and suitable drift. Install the carrier to housing cap screws and tighten securely. If clamp (Fig. 11) was -used, remove clamp and --