Factory Component Technical Manual For John Deere Axle. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 462
Number: CTM43 (november 2006)
Bookmarks
Searchable
Model
John Deere Inboard Planetary Axle
1200 Series
1400 Series
1600 Series
Contents
-SAFETY
Recognize Safety Information
Handle Fluids Safely-Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Handle Chemical Products Safely
Avoid High-Pressure Fluids
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Avoid Harmful Asbestos Dust
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Construct Dealer-Made Tools Safely
Dispose of Waste Properly
Live With Safety
-GENERAL
General Inboard Planetary Axle Specifications
Axle Identification
Serial Number Plate
Specification and Configuration Code Plate – 1200 Series
Specification and Configuration Code Plate – 1400 Series
Serial Number Plate—OEM Applications—1600 Series
General Repair Procedures
Sealants and Adhesives Cross-Reference Chart
Sealing Instructions
Transmission, Hydraulic, and Gear Case Oil
Service and Maintenance Schedule
Standard and Extreme Duty Axle—Oil Capacity (Approximate)
Super Wide Extreme Duty Axle—Oil Capacity (Approximate)
Check, Drain, and Refill Axle Oil—Standard and Extreme Duty Axles
Check, Drain, and Refill Axle Oil
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Grease
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values— Grade 180
Hydraulic Connections
-1200-1400 OSCILLATION SUPPORTS
Essential or Recommended Tools
Other Material
Specifications
Cross-Sectional View—Input Housing/Cover
Exploded View—Dual Input Oscillating Supports
Remove Input Oscillating Support
Disassemble and Inspect Input Oscillating Support
Assemble Input Oscillating Support
Install Oscillating Support—Non-helical Input Spline Axles
Install Oscillating Support—Helical Input Spline Axles
Remove. Disassemble, and Assemble Oscillating Support from Opposite End of Input
-1600 OSCILLATION SUPPORTS
Essential or Recommended Tools
Other Material
Specifications
Cross-Sectional View—Input Quill—Oscillating
Remove Oscillating Support
Disassemble Oscillating Support
Assemble Oscillating Support
Install Oscillating Support
Remove and Install Pivot Pin
Remove, Disassemble, and Assemble Oscillating Support from Opposite End of Input
-AXLE ASSEMBLY END PLAY
Specifications
Adjust Axle Assembly End Play-In Vehicle
-1200-1400 NON-HELICAL INPUT SPLINE AXLE INPUT HOUSING
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Input Housing
Cross-Sectional View—Input Housing/Cover
Exploded View—Input Housing/Cover
Disassemble and Assemble Input Housing
Determine Differential Drive Shaft Cone Point Shim Pack
Continue Assembly
Adjust Input Pinion Shaft End Play
-1400 HELICAL INPUT SPLINE, INPUT HOUSING
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Input Housing
Cross-Sectional View—Input Housing/Cover
Exploded View—Input Housing/Cover
Disassemble and Assemble Input Housing
Determine Differential Drive Shaft Cone Point Shim Pack
Continue Assembly
Adjust Input Pinion Shaft End Play
-1600 INPUT HOUSING/CASE COVER
Essential or Recommended Tools
Other Material
Specifications
Install Axle in Repair Stand
Remove Input Housing/Cover
Cross-Sectional View—Input Housing/Cover
Exploded View—Input Housing/Cover
Disassemble Input Housing/Cover and Bevel Pinion Shaft
Assemble Input Housing/Cover and Bevel Pinion Shaft
Determine Differential Drive Shaft Cone Point Shim Pack
Continue Assembly of Input Housing/Cover
Install Input Housing/Cover
-DISCONNECT AND INPUT HOUSING/CASE COVER
Essential or Recommended Tools
Other Material
Specifications
Cross-Sectional View—Axle Disconnect and Input Housing/Case Cover
Cross-Sectional and Exploded Views—Axle Disconnect
Remove Disassemble and Assemble Axle Disconnect
Cross-Sectional and Exploded Views—Input Housing/Case Cover
Remove Input Housing/Case Cover
Disassemble Input Housing/Case Cover and Pinion Shaft
Assemble Input Housing/Case Cover and Pinion Shaft
Determine Differential Drive Shaft Cone Point Shim Pack
Continue Assembly
Adjust Pinion Shaft
Install Input Housing/Case Cover
Install Axle Disconnect
-1200-1400 DIFFERENTIAL HOUSINGS
Essential or Recommended Tools
Other Material
Specifications
Exploded View—Differential Lock Lines— Air Boost System
Exploded View—Differential Lock Lines— Suction Tube
Cross-Sectional View—Differential Assembly With Differential Lock
Remove Differential Housing Assembly
Disassemble, Inspect, and Assemble Differential Housing
Assemble and Test Differential Lock Quill
Remove and Install Rina Gear
Disassemble, Inspect, and Assemble Differential Pinions
Cross-Sectional View—Differential Assembly—NoSPIN
Exploded View—Differential Assembly—NoSPIN
Disassemble, Inspect, and Assemble NoSPIN Differential
Install Differential
Adjust Differential Bearing Preload
Adjust Differential Backlash
Install Differential Lock Lines
Install Housing/Cover
-1400 JOHN DEERE GRADER DIFFERENTIAL HOUSING
Essential or Recommended Tools
Other Material
Specifications
Remove Differential Lock Valve
Install Differential Case Assembly in Repair Stand
Remove Input Housing/Cover
High Pressure—Differential Housing with Differential Lock
Low Pressure—Differential Housing with Differential Lock
Remove Differential Housing
Disassemble, Assemble, and Test Differential Lock Quill
High Pressure—Disassemble Differential Housing
Low Pressure—Disassemble Differential Housing
Remove and Install Ring Gear
High Pressure— Assemble Differential Housing
Low Pressure—Assemble Differential Housing
Install Differential Housing
Adjust Differential Bearing Preload
Install Differential Lock Lines
Install Input Housing/Cover
Adjust Differential Backlash
Differential Lock Valve Exploded View – Solenoid Valve
Remove and Install Differential Lock Solenoid Valve
Differential Valve Group Exploded View
Install Differential Lock Valve
-1600 DIFFERENTIAL HOUSING
Essential or Recommended Tools
Other Material
Specifications
Install Axle in Repair Stand
Remove Differential Housing
Cross-Sectional View—Differential with Differential Lock
Cross-Sectional View—Standard Differential
Disassemble, Inspect, and Assemble Differential Housing
Install Differential Housing
Adjust Differential Preload
Adjust Differential Backlash
-1200-1400 STANDARD AND EXTREME DUTY AXLE FINAL DRIVE
Essential or Recommended Tools
Other Material
Specifications
Exploded View—Axle Shaft and Housing—Greased Outer Bearing
Exploded View—Axle Shaft and Housing—Greased Outer Bearing with Spacer
Exploded View—Axle Shaft and Housing— Oiled Outer Bearing Axles
Exploded View—Final Drive
Remove Axle Housing Assemblies
Remove Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Disassemble and Assemble Axle Housing
Assemble Final Drive/Axle Housing Assembly
Cross-Sectional View—Planet Pinion Carrier and Axle Shaft
Cross-Sectional View—Final Drive Hub and Axle Shaft—1200 Series
Disassemble Planet Pinion Carrier
Inspect Planet Pinion Components
Assemble Planet Pinion Carrier
Assemble Axle Shaft and Housing
Adjust Axle Bearings
Install Axle Housing Assemblies
Torque Turn Tightening Procedure
Fill Axle Housing with Grease (Greased Outer Bearing Axles)
-1400 JOHN DEERE GRADER PLANETARY CARRIER
Essential or Recommended Tools
Other Material
Cross-Sectional View—Planet Pinion Carrier
Disassemble Planet Pinion Carrier
Inspect Planet Pinion Components
Assemble Planet Pinion Carrier
Inspect and Install Final Drive Rina Gear
-1400 JOHN DEERE EXTREME DUTY PLANETARY CARRIER
Specifications
Cross-Sectional View—Planet Pinion Carrier
Disassemble, Inspect, and Assemble Planet Pinion Carrier
-1400 SUPER WIDE EXTREME DUTY AXLE HOUSING, SHAFT, AND FINAL DRIVE
Essential or Recommended Tools
Other Material
Specifications
Exploded View—Axle Shaft and Housing
Exploded View—Final Drive
Remove and Disassemble Axle Housing Assemblies
Disassemble, Inspect, and Assemble Axle Shaft
Cross-Sectional View—Planet Pinion Carrier
Disassemble, Inspect, and Assemble Planet Pinion Carrier
Install Axle Face Seals
Install Axle Housing to Axle Shaft
Adjust Axle Bearings
Install Axle Housing Assemblies
-1600 FINAL DRIVE/PLANETARY CARRIER
Essential or Recommended Tools
Other Material
Specifications
Install Axle Assembly in Repair Stand
Remove Final Drive Assemblies
Install Final Drive Assemblies
Cross-Sectional View—Final Drive and Axle Assembly—Oiled Outer Axle Bearing
Exploded View—Axle Shaft and Housing—Oiled Outer Axle Bearing
Cross-Sectional View—Final Drive and Axle Assembly Greased Outer Axle Bearing
Exploded View—Axle Shaft and Housing Greased Outer Axle Bearing
Disassemble Final Drive
Exploded View—Final Drive Planetary Carrier
Disassemble Planet Pinion Carrier
Inspect Planet Pinion Components
Assemble Planet Pinion Carrier
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Install Axle Housing
Adjust Axle Bearings
-1200-1400 SINGLE DISK BRAKES
Essential or Recommended Tools
Specifications
Exploded View—Brake Components—Early Design—Three Dowel
Exploded View—Brake Components—Later Design
Exploded View—Brake Components—Later Design—Retained Backing Plate
Disassemble and Assemble Brakes
-1600 SINGLE DISK BRAKES
Specifications
Cross-Sectional View—Brake Components
Exploded View—Brake Components
Disassemble and Assemble Brakes
-1400 MULTIPLE DISK BRAKES
Essential or Recommended Tools
Specifications
Brake Inspection—Hydraulic Brakes
Cross-Sectional View—Brake Components—Multiple Disk Brakes
Exploded View—Brake Components—Multiple Disk Brakes
Remove and Install Brake Components from Differential Case
Brake Piston Packings—Vacuum Leakdown Test
-PARKING BRAKE
Essential or Recommended Tools
Specifications
Cross-Sectional View—Manual Park Brake
Remove, Assemble, and Adjust Park Brake— Manual
Cross-Sectional View—Spring Applied/Hydraulic Release Park Brake
Remove. Assemble, and Adjust Park Brake— SprinaApplied/Hvdraulic Release
-DRY DRUM BRAKE
Specifications
1400 Series Dry Drum Brake Axle
Remove Brake Drum
Inspect Brake Drum
Remove Brake Adjuster
Remove Camshaft and Air Chamber Bracket
Inspect Air Chamber Inner Bracket
Inspect Spider Assembly
Remove and Install Spider Assembly
Install Air Chamber Bracket and Camshaft
Install Brake Adjuster
Install Brake Drum
-TROUBLESHOOTING
Troubleshoot Axle and Differential
-BRAKE INSPECTION, ADJUSTMENTS, TESTS, AND BLEEDING
Adjust Park Brake—Spring Applied/Hydraulic Release
Park Brake Pressure Test
Adjust Park Brake—Manual
Brake Disk Inspection (External)
Annular Brake Piston Inspection
Leakdown Test—Brake Piston Packings
Bleed Hydraulic Brakes
-OPERATIONAL CHECKS
Axle Vertical Movement Check
Check Carrier Backlash
Check Ring Gear and Pinion Tooth Contact Pattern
-DIFFERENTIAL AND AXLE ASSEMBLY TESTS
Air Test Differential Lock Capture System
Oil Test Differential Lock Capture System
Test Differential Lock Sealing Rings with Air Boost System
Air Test Standard and Extreme Duty Axle Assembly
Air Test Axle Assembly—Super Wide Extreme Duty Axle
NoSPIN Differential—Installation Test
NoSPIN Differential—Operation Test
NoSPIN Differential Test
Differential Lock Function Test
-THEORY OF OPERATION
Axle Oscillation
Axle Disconnect Operation
Inboard Planetary Axle Operation
Differential Operation
Standard Differential Operation
Dif-Lok Differential Operation
NoSPIN Differential Operation
Capture System Operation
Air Boost System Operation
Pressurized Differential Case Operation
Standard and Extreme Duty Final Drive/Axle Operation (Oiled Outer Axle Bearing)
Standard and Extreme Duty Final Drive/Axle Operation (Greased Outer Axle Bearing)
Super Wide Extreme Duty Final Drive/Axle Operation
Service Brake Operation—Single Disk
Service Brake Operation—Multiple Disk
Park Brake Operation—Manual
Park Brake Operation—SAHR
Dry Drum Brake Operation
-DEALER FABRICATED TOOLS
Fabricated Tools
DF1055—Yoke Holding Tool
DF1057—Axle Adjusting Tool
DFRW7A—Differential Lifting Tool For 1400 Series
DFRW30—Axle Jacking Tool
DFRW102—Pinion Shaft Tool
DFRW143—Axle Housing and Inner Bearing Removal Tool
Speedi Sleeve Installation Tool
Quill Alignment Tool
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