Operation CHARM: Car repair manuals for everyone.

Locking

Fig. 7 Governor & Latch Bracket Bushing Removal.:




Fig. 12 Eaton locking differential exploded view. Models w/8-7/8 inch ring gear:





Differential Case Disassembly

1. Note the position of the governor and latching bracket assembly. Remove the ring gear and side bearings.
2. Using bushing puller tool No. J-26252, remove governor assembly and latching bracket by pulling the retaining bushings, Fig. 7. Pull the latching bracket spring out of the way while pulling the governor assembly bushing to prevent damage. Remove the stop pin by driving through the case with a drive pin punch, Fig. 12.
3. Remove lock screw and pinion shaft, and roll out differential pinion gear.
4. Remove thrust block and pinion thrust washers.
5. Remove the cam gear, disc pack assembly and disc pack guide clips.
6. Remove side gear, disc pack assembly and shim.
7. Clean and inspect all parts. Replace parts as needed. The following parts are serviceable components: governor assembly and latching bracket with spring and stop pin, cam plate, clutch disc pack with guides, pinion cross shaft, pinion gears, pinion thrust washers, reaction block, thrust ring, flange end shim. Attempts to service other components may disturb critical clearances. If reaction block or flange and shim must be replaced, the original pieces must be carefully measured for thickness and replaced with a piece of the same size. If differential case, cam gear and/or side gear is damaged or defective, entire differential assembly must be replaced.


Fig. 12 Eaton locking differential exploded view. Models w/8-7/8 inch ring gear:





Cam Gear (L.H. Side) Clutch Service
If cam plate or clutch discs must be replaced, the cam gear subassembly must be serviced as follows:
1. Measure and record overall length of gear assembly (front face of gear to back side of thrust ring, including shim). This dimension will be needed to reassemble unit if thrust ring is replaced. Do not replace thrust ring unless necessary. If ring is excessively worn or scored, check bore in case for scoring. If bore is scored, replace entire differential.
2. With gear hub end up, compress disc pack and install jaws of split ring bearing remover between the thrust ring and the top eared disc. Bevel side of bearing remover should face up toward thrust ring.
3. Place cam gear assembly with bearing remover attached in an arbor press supporting the bearing remover on both sides.
4. Install a 1-1/2 inch to 1-3/4 inch diameter plug on gear hub. Press against plug with ram of press to remove thrust ring. Keep components in proper order.
5. Place gear on bench with hub end up.
6. Assemble cam plate with cam form down to mate with cam form on gear.
7. Assemble onto cam plate: 2 eared discs, 1 splined disc, and 1 wave spring alternately, Fig. 12.
8. Assemble onto gear hub: 2 splined discs and 3 eared discs alternately, Fig. 12.
9. Locate cam gear assembly in arbor press with hub end up. Place thrust ring on gear hub and press to shoulder making sure that ring is square with hub. Compress disc pack by pushing down on the discs to keep the splined discs from becoming wedged between the thrust ring and gear shoulder while pressing the subassembly together.

Side Gear (R.H. Side) Clutch Service

1. Remove shim and disc pack from side gear, keeping components in order.
2. Inspect discs and guide clips and replace as needed.
3. Inspect side gear and shim. If either component is damaged or excessively worn, differential assembly must be replaced. If gear hub is scored or abnormally worn, inspect corresponding bore in case. If case bore is damaged or oversize, differential assembly must be replaced.
4. Assemble eared and splined discs onto side gear hub, starting with eared disc as shown in Fig. 12. If original disc pack is used, ensure that discs are installed in original position.



Differential Case Assembly

1. Install 4 clutch pack guide clips on the ears of the cam gear clutch pack using grease for retention.
2. Install cam gear assembly and original shim in flange end of case. If a new thrust ring has been pressed on the cam gear, reshimming may be necessary. Measure the overall length of the new cam gear assembly, including the shim and compare to the dimension obtained in Step 1 of cam gear service section. If the length of the new assembly varies by more than .003 inch, larger or smaller than the original dimension, reshimming will be necessary. Incorrect shimming will result in differential failure.
3. Lock an axle shaft in vise. Mount the differential case over the end of the axle shaft engaging the spline of the side gear with the shaft. Grease the two pinion gear thrust washers and locate them in their power position. Assemble on to bell end gear hub 2 splined discs and 3 eared discs alternately, begin and end with an eared disc. Install 4 small clutch pack guide clips on the ears of the bell end clutch pack using grease for retention. Install case with original shim.
4. Insert one pinion gear through the small window opening in the case while at the same time inserting the reaction block and other pinion gear through the large window opening. Rotate the two pinion gears and thrust block 90° so as to position the reaction block with the open side toward the small window opening in the case. Be sure the two pinion gears and thrust washers are in their proper location. Reaction block must be replaced with a block of the identical thickness. Incorrect block thickness may result in differential failure.
5. Install shaft and lock screw.
6. Insert the governor assembly and latching bracket into case. Place the straight end of the latching bracket spring over and onto the outside of the engagement shaft to preload the latching bracket against the governor assembly. Press bushing and 1/4 inch stop pin into case. Press bushing for governor assembly into case to give .004 to .020 inch shaft endplay. Press bushing for latching bracket into case to remove endplay. Press stop pin flush with top of case. For the latching bracket use bushing with the tapered hole. The bushing for the governor assembly has a straight hole.
7. Install ring gear and side bearings.
8. Place differential unit in carrier and adjust ring gear and pinion backlash and gear tooth pattern.