Columbia ParCar Expediter EX21-24A, Service Manual

Page: 64 / 94

Section 7 - Rear Wheels,
Rear Suspension & Axle Assembly
9. Position differential case assembly (4) with flanged side
trunnion face down on work surface. Align output gear (5)
mounting holes with differential case. Install four bolts (6)
and nuts (7). Bolts should be installed from differential
flange side. Torque nuts to 35-45 ft. lbs. (4761 Nm). See
Figure 7-24.
10. Differential bearings (8) can be installed on differential case
(4) before or after installing ring gear. Use care not to
damage differential bearings or final gear (5) when
installing the opposite component.
11. Position housing (1) with opening facing up. Insert
differential case, output gear (5) and bearing (8) assembly
into housing. Make sure teeth of gear (5) mesh with teeth
of small gear on intermediate shaft (9) and that both turn
freely. See Figure 7- 25.
12 Install differential bearing caps (2) with bolts (3). Torque bolts
to 35-45 ft. lbs. (47-61 Nm).
13. Place a small bead of RTV (non-acidic) silicone sealant to
flange of cover plate (18). Sealant should be applied to
inside of cover plate mounting holes (Figure 7-26).
14. Install cover plate (18) with ten bolts (20). Torque bolts to
16-24 ft. lbs. (21.5-32.5 Nm).
15. Install new intermediate cup plug (17) to both sides of
housing (1). Use Loctite Safety Solvent #75559 to clean
bores, then apply Loctite RC 609 to housing bores. Cup
plugs can be installed by using a properly sized driver and
hammer. Cup plugs should be firmly seated against snap
rings (16). See Figure 7-27.
16. With properly sized seal driver, install shaft oil seals (24)
Press seals to depth of 1.125” (28.5 m). See Figure 728.
17. Install inner snap ring (25) to both right and left tubes. See
Figure 7-29).
18. Press bearings (26) onto axle shafts (22). Bearing should
seat on shoulder. Use appropriate driver to install bearings.
See Figure 7-30.
19. Coat lip of seal (24) with SAE 30 oil before inserting axle
shaft (22). Insert axle shaft assemblies into tubes. Using a
properly sized bearing driver, tap axle shaft assembly until
it is seated firmly against inner snap ring (25). Shaft may
have to be rotated to engage differential splines during
installation.
20. Install outer snap ring (25) in each tube (Figure 7-31).
NOTICE: Bearing caps are marked for identification.
Letters or numbers are stamped in horizontal and
vertical position. When reassembling, install caps back
in their original positions, using these stamps as a
guide.
Figure 7 - 26
Figure 7 - 27
Figure 7 - 2 8