Repairing a differential gear on a Komatsu 95 with a 4D95LE-2 engine involves several steps and requires a good understanding of mechanical systems, as well as the right tools and replacement parts. click here for more details on the download manual…..
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Below is a detailed guide on how to approach this repair.
### Tools and Equipment Needed
1. **Basic Tools**:
– Wrenches (metric sizes)
– Sockets and ratchet set
– Screwdrivers (flathead and Phillips)
– Pliers
– Hammer
– Torque wrench
– Pry bar
2. **Specialized Tools**:
– Bearing puller
– Differential carrier bearing adjuster
– Gear measuring tools (dial indicator)
– Transmission jack or a suitable lift
3. **Replacement Parts**:
– Differential gear set
– Bearings and seals
– Gaskets
– Oil (gear oil specific to the Komatsu specifications)
4. **Safety Equipment**:
– Safety glasses
– Gloves
– Steel-toed boots
### Steps for Differential Gear Repair
#### 1. Safety Precautions
– Ensure the machine is on a stable, level surface.
– engage the parking brake and chock the wheels to prevent movement.
– Disconnect the battery to prevent any electrical issues.
#### 2. Remove the Rear Axle Assembly
– **Detach the driveshaft**: Unbolt the driveshaft from the differential input yoke. Use a universal joint (U-joint) tool if necessary.
– **Disconnect any brake lines**: If the brake lines are connected to the axle, cap them to prevent fluid leakage.
– **Remove the axle housing**: Unbolt the axle housing from the chassis using the socket set. Carefully lower the axle assembly using a transmission jack.
#### 3. Disassemble the Differential
– **Remove the differential cover**: Unbolt the cover from the differential housing, and carefully pry it off. Expect some fluid to spill, so have a catch pan ready.
– **Inspect the oil**: Check for metal shavings or debris in the oil, which could indicate wear or damage to the gears.
– **Remove the ring gear**: Unbolt the ring gear from the differential case. Use a torque wrench to ensure the bolts are not over-torqued.
– **Take out the differential case**: Remove the differential case by pulling it out of the housing. Be cautious to avoid damaging the bearings.
#### 4. Inspect Components
– **Check gears**: Examine the condition of the ring and pinion gears for wear, pitting, or chips.
– **Inspect bearings**: Look for signs of wear or damage on the bearings. If they are worn, they will need replacing.
– **Inspect seals and gaskets**: Replace any damaged seals or gaskets to prevent leaks.
#### 5. Replace Damaged Components
– **Install new bearings**: If the bearings are worn, press new ones onto the differential case. This may require a bearing press.
– **Install the new ring gear**: If the ring gear is damaged, install a new one. Ensure it’s torqued to the manufacturer’s specifications.
– **Check backlash**: Use a dial indicator to measure the backlash between the ring and pinion gears. Adjust as necessary using the bearing adjusters.
#### 6. Reassemble the Differential
– **Reinstall the differential case**: Carefully slide the differential case back into the housing.
– **Reattach the ring gear**: Ensure all bolts are torqued to the specifications.
– **Replace the differential cover**: Clean the surface
and apply a new gasket or sealant before reinstalling the cover.
#### 7. Reinstall the Rear Axle Assembly
– **Lift the axle assembly back into position**: Use a transmission jack to help align it properly.
– **Reattach the driveshaft**: Securely bolt the driveshaft back to the differential input yoke.
– **Reconnect brake lines**: If they were disconnected, ensure they are reattached securely.
#### 8. Fill with Gear Oil
– **Fill the differential**: Use the appropriate gear oil and fill the differential through the fill plug until it reaches the recommended level.
#### 9. Final Checks
– **Check for leaks**: Before putting the machine back into action, check for any leaks around the differential cover and axle housing.
– **Test the differential**: Run the machine at low speed to ensure proper operation.
#### 10. Clean Up
– Dispose of the old oil and any worn-out parts according to local regulations.
### Conclusion
Repairing the differential gear on a Komatsu 95 4D95LE-2 engine is a detailed process that requires careful attention to detail and proper tools. Always refer to the manufacturer’s service manual for specific torque specifications and procedures, as these can vary by model and year. If you’re unsure about any step, consult a professional mechanic or technician.
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