Differential Gear, Disassembling and Assembling

DIFFERENTIAL GEAR, DISASSEMBLING AND ASSEMBLING





NOTES:
^ Heat tapered roller bearing inner race to 100°C (212°F) before installing.
^ Always replace both tapered roller bearings together as a set.
^ If the tapered roller bearings for the differential housing, final drive cover, drive pinion set and the transmission housing are replaced, the differential must be adjusted.
^ An asterisk (*) indicates adjustment work is required if these components are replaced.
1. Final drive cover*
2. O-ring for cover
^ Always replace
^ Insert using oil
3. Final drive housing*
4. Shim S1
^ Note thickness
^ Adjustment overview - Refer to Differential; Adjustments.
5. Small tapered roller bearing outer race*
^ Driving out refer to Fig. 1
^ Pressing in refer to Fig. 2
6. Small tapered roller bearing inner race*
^ Pulling off refer to Fig. 3
^ Pressing on refer to Fig. 4
7. Ring gear bolt
^ Always replace
^ Use only genuine replacement bolts
^ Counter-hold when tightening
^ Tighten in diagonal sequence
^ Tightening torque: 60 Nm (44 ft. lbs.) plus additional 1/8 turn (45°)
8. Differential gear housing*
9. Ring gear*
^ Matched with pinion (in ring gear and pinion set)
^ When replacing set, pinion and ring gear must be adjusted
^ Drive out of differential gear housing using mandrel refer to Fig. 9
^ To install, warm ring gear to 100°C (212°F)
10. Roll pin
^ For securing axle for differential bevel gears
^ Drive in flush
11. Large tapered roller bearing inner race*
^ Pulling off refer to Fig. 5
^ Pressing on refer to Fig. 6
12. Large tapered roller bearing outer race*
^ Driving out refer to Fig. 7
^ Pressing in refer to Fig. 8
13. Shim S2
^ Note thickness
^ Adjustment overview - Refer to Differential; Adjustments.
14. Threaded piece
15. Differential bevel gears, large
^ Installing refer to Fig. 11
^ Adjusting
16. Differential bevel gears, small
^ Installing refer to Fig. 11
17. Axle for differential bevel gears
^ Drive out using mandrel
18. Shim Determining thickness
19. Thrust washer
^ Check for cracks





Fig. 1 Driving small tapered roller bearing out of final drive housing
- After removing, check shims for damage.





Fig. 2 Driving outer race of small tapered roller bearing into final drive housing
- Press into stop.





Fig. 3 Pulling inner race of small tapered roller bearing off of housing
A - Two arm puller (commercially available), e.g. Kukko 44/2





Fig. 4 Pressing on inner race of small tapered roller bearing
- Warm bearing to approx. 100°C (212°F), install and press down.





Fig. 5 Pulling off inner race of large tapered roller bearing
- Place 40 - 105 thrust piece on differential gear housing before installing pulling device.





Fig. 6 Pressing on inner race of large tapered roller bearing
- Warm bearing to approx. 100°C (212°F), install and press down.





Fig. 7 Driving outer race of large tapered roller bearing out of cover
- After removing, check shims for damage.





Fig. 8 Pressing outer race of large tapered roller bearing into cover





Fig. 9 Driving ring gear off housing





Fig. 10 Installing ring gear
- Warm ring gear to approx. 100°C (212°F) and install.
A - Centering pins (hand-made); use as guide

WARNING: Wear protective gloves when performing this step.





Fig.11 Installing differential bevel gears
- Shims must be redetermined if large differential bevel gears have been replaced.
- Install large differential bevel gears together with proper shim.
- Install small differential bevel gears (turned 180°) and swing in (hold thrust washer in place with some grease).
- Align thrust washers.
- Install threaded pieces.
- Drive in axle for differential bevel gears and secure.

ADJUSTING DIFFERENTIAL BEVEL GEARS
- Install large differential bevel gears together with 0.50 mm shims.
- Install small differential bevel gears together with thrust washers and press in axle for differential bevel gears.
From this point on,the differential bevel gears must be kept together with their respective thrust washers.
- Drive in planet pinion shaft.





- Press small differential bevel gears outward and check play of large differential bevel gears by hand (arrows).
- Determine thickest shim (that can still just be fitted) for differential bevel gears on each side.
- Select shims of same thickness.





Table of shims






TURNING DIFFERENTIAL BEVEL GEARS
If no play is perceptible, the bearing clearance cannot be measured, and it is still possible to turn the bevel gears, the adjustment is correct.