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Lull 1044c-54 series2 front diff

Discussion in 'Forklifts/Telehandlers' started by 93NELSON, Feb 24, 2020.

  1. 93NELSON

    93NELSON Member

    Joined:
    Nov 4, 2019
    Messages:
    6
    Location:
    Iowa
    Just did my second front diff repair on this series 2. New clutch disc assembly with side gears and shafts. Did assembly and clearance spec was good. Soaked friction discs over a weekend. Put it back together and installed in housing. Completed and ran it out the shop. Seems fine going forward but starts acting up turning left. (Popping sound). When turning right it just seems like it’s tight. Removed rear drive shaft and put front wheels in the air. Front spins in gear fine. Brought it back in and took it back apart. No damage besides a few scars on a couple side gears. Put it back together and the clearance is a little off.

    spec is .20mm and I got .30ish
    I know that the clearance is more but...
    If you have some experience with this is this issue a loose issue or would it be more if it was tight.
    Just trying to learn.

    The first one I did I did this the same way with no issues.

    if it matters...
    Service tech at a construction company.

    thanks
     
  2. tractormech

    tractormech Well-Known Member

    Joined:
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    Messages:
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    Location:
    florida
    Do the clutch discs slide on the axle side gears? (side gears have splines) Sometimes there are thick and thin discs-did you check and be sure you had the correct number and thickness of discs? Did all the splines on the discs go up on the axle gear? Did you replace the spider gears too? What kind of differential do you have? Serial number of the machine will help.
     
  3. 93NELSON

    93NELSON Member

    Joined:
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    So this will sound crazy. we put new clutch discs, plates, side gears and spider gears with the new shafts. Turns out the spider gears are wrong and you can barely tell. Everything spins fine until you put a load on it like steering the machine.

    I put the old spider gears in and I’ll see what happens. I’m sure it will be fine.

    The first one I did we took all long time to do because of the concern of getting the right clearances with the clutch/spacer discs so I knew this time around it wouldn’t be a big deal. Though with this problem I was lost until I looked over the gears.
     
  4. tractormech

    tractormech Well-Known Member

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    It sounds like you figured it out. Let us know how it does,
     
  5. 93NELSON

    93NELSON Member

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    It’s good to go. Never crossed my mind that the spider gears could be wrong.
     
  6. tractormech

    tractormech Well-Known Member

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    If they are slightly larger they will push the side gears out and make the discs bind up. Had something just like it on an old Spicer diff in a Lull one time. I just happened to notice the carrier wasn't going back together as close as before-started checking and found spider gears too big. Just some more "experience" I guess.
     
  7. 93NELSON

    93NELSON Member

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    These were a little smaller and they obviously weren’t meshing with the side gears.
     
  8. tractormech

    tractormech Well-Known Member

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    The new ones? that explains the popping noise. The spider gears were too small in diameter and when the thrust and torque makes the gears force away from each other and they pop and slip. When the discs in the no slip wear it creates clearance behind the axle side gear and it has too much clearance. I've seen them wear to a point that the differential will pop and slip so bad it won't pull at all. You'd think the ring and pinion had teeth knocked off the way it sounds. We use them on the beach and they wear heavily in the sandy conditions.The carrier isn't worn where the thrust washers ride on the side gears is it? check that.
     
  9. 93NELSON

    93NELSON Member

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    before I took it apart it didn’t make a whole lot of noise but the front wasn’t pulling. Took it apart. Friction discs had nothing left and the side gears they were on had grooves in them. So replaced all that with new spiders and didn’t think to check them cus they looked the same at first glance.

    The first one I did a couple months ago the spacer plates on one side broke all the tabs off the everything fused together.
     
  10. tractormech

    tractormech Well-Known Member

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    Location:
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    Yours was worse off than mine apparently. Glad you got it together.