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Service assembly of the main transfer
 | To perform the procedures described below require the following special tools: Stillson wrench and puller input flange (to replace the pinion oil seal); the above-mentioned tools, plus bearing puller (for dismantling); Press the base plate, sensitive low-range torque wrench measurement and dial gauge (to build). |
Replacing the gland pinion | - Poddomkratte the front of the car and establish it on props, the institution under the frame side members.
- Remove the drain plug and drain the oil from the crankcase of the front axle.
- Mark the position of the front propeller shaft with respect to the pinion flange, then remove the driveshaft flange and tie it to the side of the frame to the spar using the length of wire.
- Mark the position of the pinion in relation to its flange (drive pinion with the associated components is shown in the accompanying illustration).
- Fix the flange still using a large wrench Stillson and give a nut pinion.
- With the help of a stripper remove the flange with the gear.
- Using a hammer with sliding brisk or a suitable lever, remove the oil seal from the crankcase.
- Strip the slot for the installation of the gland in the housing and check the walls for the presence of burrs and scoring.
- Type in the space between the lips of new oil seal multi-purpose grease on lithium basis. Grease with special greasing the outer edge of the gland, and set the last perpendicular to the crankcase main gear flush with its end.
- Using a hammer with soft brisk replace the pinion gear, having tracked registration deposited in the process of dismantling tags.
- Lubricate the sealing nut, put the washer and tighten the nut to 196 ÷ 284 Nm.
- Connect to the flange of the propeller shaft (Track registration deposited in the process of dismantling marks). Tighten the mounting bolts to 78 ÷ 88 Nm.
- Fill the axle housing required amount of oil demanded grade (see. Table sizes and adjustments in the end of this manual).
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Refitting Withdrawal | - Remove the front wheel and drive shafts.
- Mark the position of the front propeller shaft with respect to the flange of the drive pinion, and then disconnect from the shaft flange. Tie up the shaft to the side frame member by means of a length of wire.
- Give fixing nuts, washers and release the brake pipe from an arm. Remove the assembly from the crankcase main gear of the front axle. Remove from assembly and discard gasket.
| The drafters of the Guidelines recommend the use for the removal of the main transmission via an assistant - the weight of the assembly is very significant. |
- Check the axle housing for the presence of metal chips inside, the presence of which should be seen as a sign of deterioration of the main transfer. This assembly must be completely disassembled and replace defective or worn components.
- Sand mating surfaces axle housing and final drive assembly. Make sure that no debris has not got into the crankcase.
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Setting Installation is in the reverse order. | - Replace the axle housing a new gasket (gray side of the bridge).
- Install final drive assembly, screw the fixing nuts and tighten them with a force of 54 ÷ 64 Nm.
Connect the propeller shaft. Ensure registration deposited in the process of dismantling the labels. Tighten fasteners to torque 78 ÷ 88 Nm. - Replace the drive shaft and the hub of the front wheel. Fill the axle housing required amount of oil demanded grade (see. Table sizes and adjustments in the end of this manual).
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Dismantling | - Remove assemblage of the main transfer. Clamp it in a vise.
- Before proceeding to dismantle the assembly, check the following:
- Using a dial gauge, installed in front of the mating surface of the crankcase assembly, check the beating of the ring gear. If the measured value exceeds 0.08 mm, check Do not hit between the gear box and differential debris. If those can not be found, replace the differential case.
- Using a dial gauge, check radial play idler four points. The nominal value of the clearance is 0.15 ÷ 0.20 mm. When exceeding the specified value measurement result in any of the scanned points (if permissible value heartbeat) replace the mandatory slave and master gears or differential box (as appropriate).
- Apply landing marks on the cover side bearings and the adjacent surface of the housing of the main transfer (see. Accompanying illustration).
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- Remove the locking tabs with the side bearing caps, give fixing bolts and remove the cover and adjusting nuts.
- Wooden arm prop driven gear assembly with differential, pushing them out of the crankcase main gear. Try not to mix up the cage side bearings - to ensure they put identification tags.
- Mark the position of the satellites relative to the axis of the pinion flange.
- Fix the flange great Stillson wrench and give the pinion nut.
- With the help of a stripper remove the flange with the pinion gear, then remove the crankcase itself gear, spacer sleeve and shims (if necessary, use a hammer with soft brisk).
- Using a hammer with sliding brisk or a suitable lever, remove the oil seal from the crankcase and then remove the outer bearing cone pinion.
- Mark the landing position of the driven gear on the box of differential.
- Straighten the locking plate (if any) mounting bolts driven pinion.
- Where required, bend the tabs lock plate bolts driven gear.
- Take in diagonal order bolts driven gear, remove and discard the retaining plate (if any).
- Using a hammer with soft brisk carefully Tap the driven gear on the perimeter to separate it from the differential housing.
- On models with 2-satellite differential (the components are shown in the accompanying illustration) using the punch knock out locking pin axis of the satellite box to the reverse side of the differential drive gear and remove the axis of satellites, satellites, differential side gears and thrust washers.
- On models with 4-satellite differential (see. Accompanying illustration) mark the installation position of the differential housing halves (of the cover and the box itself), then give the bolts them together. Divide the differential case half and take out the axes of the satellites, satellites, side gears and thrust washers.
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Cleaning and checking the status of components | - Wash all the components in a solvent and dry them with compressed air.
- Check the teeth of the driven and driving gears for signs of wear, chips and other damage.
- Check satellites, differential side gears, thrust washers, and an axis of satellites for signs of wear or damage.
- Inspect differential case for cracks and other damage.
- Check the side bearings and cups for signs of wear and tear, discoloration and other damage. If necessary, remove the bearing cone from the box by means of a stripper.
- Check the pinion bearings for signs of wear and tear, discoloration and other damage. If necessary, replace the bearings, for which:
- Using a suitable puller, remove the pinion cone of inner bearing and the spacer sleeve (if installed).
- If necessary, put on the drive pinion spacer sleeve. Make sure that the sleeve has been installed to the bevelled end gear. With the help of the press to the base plate, install a new bearing cone. Remember that the force must be applied only to the inner race of the bearing and until it stops in the remote bush hanger pinion.
- With a brass drift, remove the bearing cups from the crankcase main gear.
- Carefully place the new cup into the crankcase to a solid stop them in hangers.
- Check in contact with the surface of the gland flange pinion for scoring and wear. If necessary, replace.
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Assembly Installation is the reverse order of removal. | - Lubricate the components required grade lubricant composition.
- On models with 2-satellite differential gear box assembly make:
- Set in a box side gears, thrust washers, satellites and an axis of satellites. Do not install at this stage of the locking pin.
- With the probe blade ti-na measure the gap between the side gear thrust washer and the wall of the differential housing. If the result of measurement falls outside the range 0.15 ÷ 0.20 mm, adjust to the new thrust washers corresponding thickness.
- Align the pinion gear shaft by aligning the lock holes and replace the pin until it is fully seated in the differential box.
- Grease lubrication required grades satellites and side gears and check the freedom of their rotation.
- On models with 4-satellite differential gear for the assembly of the box:
- Set in the main half of the box side gears, thrust washers, satellites and satellite assembly axes.
- Press measuring flatness (rib steel ruler) to the back surface of the side gear thrust washer from the top side of the differential and locking the rotation of the gear, measure the distance between the mating surface of the differential housing and edge flatness meter vernier caliper using. Record the result of measurement (A).
- Press the meter to the flatness of the mating surface of the cover and the differential housing using vernier calipers, measure the distance between the contact surface of the thrust washer and side gear edge meter. Record the result (B).
- Calculate the clearance side gear thrust washer by subtracting the size in the size of A. If the calculation result is beyond the interval 0.15 ÷ 0.20 mm adjust the thrust washers to the new, desired thickness.
- Gather together the two halves of the differential housing (Track registration deposited in the process of dismantling the landing labels). Screw fixing bolts and tighten them with a torque of 64 ÷ 74 Nm.
- Grease lubrication required grade differential gears and thrust washers and check free rotation of the gear.
- On models with 2-satellite differential gear locking grease sealant contact with the ring gear surface of the differential housing.
- Install the driven gear in the differential case, if necessary, using a hammer with soft brisk. Ensure alignment caused during the dismantling of the landing labels.
- Grease the fixing sealant driven gear mounting bolts, screw bolts, setting them under the new lock plate (if any).
- Tighten bolts to 132 ÷ 152 Nm in diagonal order, while tapping lightly on their heads with a hammer. Where you want to fold the boxes locking plates using a center punch.
- Grease the outer edge of a new oil seal pinion grease required grades. Universal grease based on lithium fill the space between the oil seal lips. Install the bearing and the crankcase oil seal.
- Lubricate the rear pinion bearing lubrication required grade, then set into the crankcase pinion gear, spacer sleeve and shim. Holding the gear stationary, with a hammer with soft brisk zastuchite her flange.
- Make sure the threads on the drive gear and fixing nut are not stained with grease or oil, lubricate the threads of the nut sealant.
- Install washer, then screw the nut and tighten it with a force of 196 ÷ 284 Nm.
- Several times turn the pinion gear in both directions. Put on fixing Gaku torque wrench and determine gear bearing preload. If the amount of preload beyond the 1.3 ÷ 1.6 Nm, change the shim bearing on the other, the appropriate thickness.
- Place cups on the side bearing cones and put the differential assembly to the driven gear in the main transmission housing, making sure that the cup bearing housed properly. If you used the old side bearings, make sure that their cups were set to the same parties as before dismantling.
- Screw the adjusting nuts of the side bearing, having tracked correctness baiting them into the thread in the crankcase main gear.
- Achieve combination of landing labels covers the side bearings and the final drive housing, and install the bearing caps by hand tighten bolts of their fastening. If the cap sits on exactly when pressed against her hand, the adjusting nut bearing correctly aligned with the cover.
- Using a dial gauge, check radial play ring gear. If the result is greater than 0.02 mm, loosen the adjusting nut from the pinion gear and pull on the same number of revolutions of the opposite. If the clearance is less than 0.15 mm, follow the procedure in reverse.
| If the axial play is different at different points of the driven gear, make sure you do not fall between the gear box and differential debris. If such particles can not be identified, replace the master and slave gear box or differential. |
- Several times turn the pinion gear in both directions, and then with a torque wrench, worn by a nut of its fastening, check the total differential of the preload. If the result is outside the range 1.8 ÷ 2.5 Nm, respectively, give or tighten both adjusting nuts. Having achieved the desired value of the differential preload, re-check the radial play of the driven gear.
- Tighten the side bearing caps with effort 93 ÷ 103 Nm.
- Install locking tabs and tighten the bolts of their fastening. Pressing the plunger dial gauge to the supporting surface, check the amount of run-out ring gear. If the measured value exceeds 0.8 mm, remove the gear box with differential and check did not get there between debris.
- Coat the surface of the teeth of the driven gear Prussian blue, red lead or a mixture of butter, then fixing the pinion flange, rotate driven in both directions.
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- Inspect the surface of the teeth of the driven gear compare the shape of the contact patch with the attached background map (see. Accompanying illustration). If the desired shape of the contact can not be reached, the two gears (master and slave) must be replaced.
- Install final drive assembly, drive shafts and hubs of the front wheels.
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