Differential and Bevel Gear 966 Install

966H Wheel Loader A6D00001-UP (MACHINE) POWERED BY C11 Engine(SEBP374...
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Product: WHEEL LOADER
Model: 966H WHEEL LOADER A6D
Configuration: 966H Wheel Loader A6D00001-UP (MACHINE) POWERED BY C11 Engine
Disassembly and Assembly

966H and 972H Wheel Loaders Power Train
Media Number -RENR8847-07 Publication Date -01/03/2013 Date Updated -04/03/2013
i04160415
Differential and Bevel Gear - Install

SMCS - 3254-012-WH; 3258-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
1P-2420 Transmission Repair Stand 1
A FT-0996 Positioning Gp (Axle Repair) 4
FT-0957 Positioning Gp (Axle Repair) 4
B 138-7573 Link Bracket 2
C 138-7574 Link Bracket 2
F 186-0240 Spanner Wrench As 1
G 186-0241 Spanner Wrench As 1
H 4C-5597 Anti-Seize Compound 1
J 1U-6690 Socket Wrench As 1
K 9S-7354 Torque Wrench Gp 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly
cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to
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966H Wheel Loader A6D00001-UP (MACHINE) POWERED BY C11 Engine(SEBP374... Page 2 of 14
dry parts. Lint may be deposited on the parts and this may cause later trouble. Inspect all parts.
If any parts are worn or damaged, use new parts for replacement.
Note: If you heat the bearing cones, allow the parts to reach a uniform temperature. Then use a
driver or a press to reset the bearing cones. Heat the bearing cones to a maximum of 135°C
(275°F) for a maximum of four hours. Lubricate the bearing cones with SAE 30 gear oil after
the bearing cones have cooled in order to prevent rust on the bearing cones.
Note: If you freeze the bearing cups, allow the parts to reach a uniform temperature. Then use a
driver or a press to reset the bearing cups. The limit for freezing the bearing cups is -29°C (-20°
F). Remove any frost and wipe the bearing cups dry. Lubricate the bearing cups with SAE 30
gear oil in order to prevent rust on the bearing cups.
Illustration 1 g00451866
Personal injury can result from being struck by parts propelled by a

released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to

release the spring force.
1. Raise the temperature of bevel gear (21) . Install bevel gear (21) on the differential assembly.
2. Use the following Steps to install two spring assemblies:
a. Install the large spring pin assembly partially into the bevel gear.
b. Install the small spring assembly into the large spring pin assembly.
c. Press the pins into bevel gear (21) . Make sure that the pins are flush with the surface of
bevel gear (21) .
3. Apply Tooling (H) to bolts (20) and to the washer face. Install the washers and bolts (20) that
hold bevel gear (21) in position. The torque for bolts (20) is 280 ± 40 N·m (205 ± 30 lb ft).
Turn each bolt by an additional 120 ± 5 degrees. Make sure that the bevel gear is seated on the
mating surface.
4. Raise the temperature of bearing cone (22) . Install bearing cone (22) on the differential
assembly.
5. Raise the temperature of bearing cone (19) . Install bearing cone (19) on the differential
assembly.
6. Install bearing cup (17) , sleeve assembly (16) , and locating pin (15) in differential housing
(18) .
7. Apply lubricant to the threads on adjusting nut (14) . Install adjusting nut (14) in differential
housing (18) . Do not install lock washer (13) and bolt (12) at this time.
8. Use Tooling (C) and a suitable lifting device to install differential assembly (9) . The weight of
differential assembly (9) is approximately 109 kg (240 lb).
Note: Use the original shim pack or a new shim pack of the same thickness. If the original shim
pack is not available, use 60 percent of a new shim pack.
9. Apply lubricant to the O-ring seal before you install the O-ring seal on the pinion housing.
Install two 152.4 mm (6.00 inch) guide bolts in the axle center housing. Install the shim pack on
the pinion housing.
10. Use Tooling (B) and a suitable lifting device to install pinion gear assembly (8) . The weight of
pinion gear assembly (8) is approximately 66 kg (145 lb).
11. Install bolts (7) . The torque for bolts (7) is 300 ± 40 N·m (220 ± 30 lb ft).
Note: The thickness of the shim pack may need to be changed when you adjust the tooth
contact pattern.
12. Install bearing cup (6) , sleeve assembly (5) and the locating pin in intermediate housing (1) .
13. Apply lubricant to the threads on adjusting nut (4) . Install adjusting nut (4) in intermediate
housing (1) . Do not install lock washer (3) and bolt (2) at this time.
14. Use a suitable lifting device to install intermediate housing (1) . The weight of intermediate
housing (1) is approximately 82 kg (180 lb). Install the three bolts that hold the intermediate
housing to the axle center housing.
15. Position the axle center housing horizontally on Tooling (A) .
16. Use Tooling (F) and Tooling (G) in order to tighten adjusting nuts (4) and (14) to a position
which maintains gear backlash and slight bearing end play.
17. Measure the torque that is required to rotate the pinion shaft. Record the measured torque. Use
Tooling (J) on the pinion shaft nut for this measurement.
18. While you are rotating the pinion shaft back and forth, tighten adjusting nut (14) to the zero
backlash position. Then back off adjusting nut (14) by 20 degrees plus the increment to the
nearest lock position.
19. Tighten adjusting nut (4) on the bevel gear group while you are rotating the pinion shaft.
Tighten nut (4) until the overall preload rolling torque that is measured at the pinion shaft is 4.5
N·m to 6.8 N·m (40 lb in to 60 lb in).
20. Tighten adjusting nut (4) to the nearest lock position.
(A) Distance of dial indicator from pinion centerline.
Note: To ensure correct assembly and correct adjustment, use Tooling (K) to measure the
rolling torque of the bevel gear group at the pinion shaft. For new bearings, the rolling torque
should be 4.5 N·m to 6.8 N·m (40 lb in to 60 lb in). For used bearings, the rolling torque should
be 2.25 to 3.4 N·m (20 to 30 lb in).
21. Place a dial indicator tangent to the spline, as shown. Make sure that the yoke or the spline
adapter is tight to the spline. Measure the backlash between bevel gear (21) and the pinion
shaft. The backlash must be 0.30 +0.12 -0.10 mm (0.011 +0.005 -0.004).
The following chart gives examples of backlash at the pinion shaft by showing the different
distances from the pinion centerline to the dial indicator.
Table 2
Examples of Backlash at Pinion Shaft
Maximum Backlash Minimum Backlash
Dimension (A) Nominal Backlash
0.28 mm (0.011 inch) 0.40 mm (0.016 inch) 0.18 mm (0.007 inch)

50 mm (2 inch)
100 mm (4 inch) 0.55 mm (0.022 inch) 0.80 mm (0.032 inch) 0.35 mm (0.014 inch)
22. If the backlash does not meet the specifications, loosen one adjusting nut and tighten the
opposite adjusting nut by the same amount. This will maintain the bearing preload.
23. After the adjustments are made, remove any dyes or paint from the gears.
24. Install lock washer (3) and bolt (2) in adjusting nut (4) . Do not bend bolt lock (4) at this time.
25. Install lock washer (13) and bolt (12) in adjusting nut (14) . Do not bend bolt lock at this time.
26. After the backlash adjustment and the preload adjustment have been made, the tooth contact
between the pinion shaft and bevel gear (21) must be checked. Use the following procedure:
a. Put a small amount of prussian blue, red lead, or paint on three or four adjacent teeth of
bevel gear (21) .
b. Rotate the pinion shaft for several revolutions in one direction. Then rotate the pinion
shaft for several revolutions in the opposite direction. Then turn the pinion shaft in the
original direction in order to observe the marked teeth.
c. The correct area of tooth contact begins near the inside end of the teeth. The contact area
should extend to a maximum of 50 percent of the length of the teeth. Illustration 10 is an
example of the correct area of tooth contact.
27. If the tooth contact looks like the marks in Illustration 11, perform the following procedure:
a. Remove some of the shims that are behind the pinion housing.
b. Repeat Steps 19 through 21 for the backlash adjustment.
c. Repeat Step 22.
28. If the tooth contact looks like the marks in Illustration 12, perform the following procedure:
a. Add shims behind the pinion housing.
b. Repeat Steps 19 through 21 for the backlash adjustment.
c. Repeat Step 22.
Note: Always make sure that the backlash adjustment is correct before an adjustment is
made to the area of tooth contact. Several adjustments to the backlash and to the tooth
contact may be necessary in order to achieve the correct adjustments. A change to gear
backlash will also change the gear contact and vice versa.
29. After the adjustments are made, remove any dyes or paint from the gears.
30. Install lock washer (3) and bolt (2) in adjusting nut (4) .
31. Install lock washer (13) and bolt (12) in adjusting nut (14) .
32. Bend the locks.
End By:
a. Install the service brakes. Refer to Disassembly and Assembly, "Service Brakes - Install".
b. Install the fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove and
Install".
c. Install the oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) -
Remove and Install".
Tue Jun 21 08:32:12 MST 2022
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966H Wheel Loader A6D00001-UP (MACHINE) POWERED BY C11 Engine(SEBP374...

Disassembly and Assembly

Differential and Bevel Gear - Install

Personal injury can result from being struck by parts propelled by a

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

2. Use the following Steps to install two spring assemblies:

15. Position the axle center housing horizontally on Tooling (A) .

20. Tighten adjusting nut (4) to the nearest lock position.

(A) Distance of dial indicator from pinion centerline.

0.28 mm (0.011 inch) 0.40 mm (0.016 inch) 0.18 mm (0.007 inch)

b. Repeat Steps 19 through 21 for the backlash adjustment.

c. Repeat Step 22.

a. Add shims behind the pinion housing.

b. Repeat Steps 19 through 21 for the backlash adjustment.

c. Repeat Step 22.

32. Bend the locks.

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