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SERYI-CAR

KEY FOR FIGURĘ 2B-7

1    Hydraulic brake linę assembly

2    Front housing truss rod

3    Lower housing truss rod

4    Clamp nut and washer (5)

5    Axle housing stud (4-15/16 in.) (2)

6    Axle housing stud (6-1/32 in.) (2)

7    Axle housing stud (3-29/32 in.)

8    Left axle housing

9    Right axle housing

10    End bearing spring ring (2)

11    Thrust washer (2)

12    Oil seal (2)

13    Roller thrust bushing (2)

14    Roller bearing retainer (2)

Figurę following name of part

15    Bearing roller (24)

16    Rear axle bearing race

(righthand)

17    Rear axle bearing race

(lefthand)

18    Bearing cup lock washer

19    Bearing housing lock screw

20    Timken bearing housing

21    Bearing cup outer race (2)

22    Spring wire lock ring (.055 in.)

23    Differential bolt nut (10)

24    Differential bolt. washer (6)

25    Lock piąte (2)

26    Differential bolt (10) indicates ąuantity necessary for one

27    Drive sprocket

28    Gear housing (right half)

29    Axle lock ring half

(.125, .130, .135 in.) (4)

30    Differential axle gear (2)

31    Right axle

32    Differential gear shaft

33    Gear spacer

34    Differential gear (2)

35    Left axle

36    Gear housing (left half)

37    Speedometer drive gear

38    Timken bearing (2)

39    Grease retainer (2) complete assembly.

CAUTION

Inspect bearing rollers and races. Replace parts that are worn, pitted, grooved or gouged. Oyersize bearing rollers (15) are available in following over-sizes:    .0002, .0004, .0006, .0008 and .001 in. Select

rollers to obtain a .0015 in. to .002 in. free fit.

Inspect condition of gears. Teeth should be smooth and without nicks, gouges and grooves.

Slightly bent axles are serviceable after straighten-ing to within .005 in. total runout. If straightening facilities are not available, slightly bent axles may be returned to the factory for repair through an authorized Harley-Dayidson dealer. Replace axles that have been badly bent. Attempts to straighten them are usually unsatisfactory.

Axle housings may be straightened if they are not kinked or bent sharply. Straightening to within .010 in. total runout is considered satisfactory. If facilities for checking and straightening housing tubes are not at hand, housings may be returned to the factory through an authorized Harley-Davidson dealer for repair.

Replace leaking grease retainers (39).

ASSEMBLING DIFFERENTIAL AND AXLE (Fig. 2B-7)

Assemble parts in reverse order of disassembly. Bolt differential housing halves together with two or morę bolts. Check axle end play. Correct amountis .003 to .005 in. If end play is not within tolerance, disassemble differential and install thicker or thinner axle lock rings (29). They are available in .125, .130 and .135 in. thicknesses. Both halves of lock rings must be same thickness, although thickness of lock rings on opposite axles may be different.

When axle end play is correct, install all housing bolts with lock plates in place across ends of differential gear shaft. Install washers and nuts with nuts drawn just snug. Feed spring wire lock ring through holes in ends of bolts (starting at grease fittings) and bend over at ends to retain draw nuts (23) tight. Bend lock piąte ears against nut flats.

ASSEMBLING AXLE HOUSING (Fig. 2B-7)

Axle housing is assembled in reverse order of disassembly.

Lubricate differential as follow$:During assemby pack both axle end bearings (14 and 15),tamped roller bearings (38) and speedomet&r drive housing with Harley-Davidson Grease-All grease After assembly fili gear housing (28 and 36 with Grease-All grease (approximately 4 oz.).

When Timken bearing housing (20) is turned into case it is bottomed and then backed off about 1/4 turn. After axle housing assembly is bolted together, ad-just Timken bearing housing through slot in axle housing as follows:    Turn bearing housing into case

until it bottoms firmly. Then turn it out 1-1/2 or 2 notches, whicheyer allows bearing housing lock screw to seat in bearing housing adjusting notch. This ad-justment provides the necessary .003 to .005 in. differential assembly end play in housing.

Be surę axle housing stud bolts (6 and 7) are j/n-stalled through holes in housing from left side and stud bolts (5) from right.

Truss rods are installed so straight portions adja-cent to differential housing castings are parallel to axle tubes. This position may be obtained by loosen-ing fitting on Iow end and tightening fitting on high end. When truss rod bearing surfaces are parallel, tighten both ends an equal amount until rod is seated in notch in housing.

Seat rods just firmly in housing notch; do not draw tight. Drawing rods tight will deflect or bow housing and axle, and wear parts rapidly.

Assemble brake linę, brake drums and wheels in re-verse order of disassembly.

Install rear axle assembly in chassis and assemble box in reyerse order of disassembly.

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