Assembly and Adjustment of Gear Assembly

Assembly and adjustment of gear assembly




Note: Each drive pinion and ring gear of a gear assembly is identified by means of a serial number which is written on both parts. In addition, the distance of the gear wheels of a given gear set in relation to each other is indicated on drive pinion.


To calculate the thickness of the compensating washer required for adjusting drive pinion, always use a data sheet. The measuring and calculating procedure on an example data sheet, described in detail, is shown in the Rear Axle Gears Adjustment Data Sheet section.




33 Press rear tapered roller bearing (B) on drive pinion (6) by means of self-made pressing-on sleeve (1). For this purpose, use side of sleeve identified with an "A".

Press-on Sleeve (self made):

A = for vehicles with small center piece.
B = for vehicles with large center piece.





34 On vehicles with ABS, press-on gear wheel (rotor) with self-made pressing-on sleeve.




35 Adjust dial gauge at approx. 3 mm preload first on measuring body (051b) to 0.




36 Slip outer bearing race on roller cage of drive pinion. Insert drive pinion into measuring device (056) and measure height of drive pinion including bearing. Enter dimension, which represents the difference between the height of measuring body "B1" and height of drive pinion "B", on data sheet item 1.

37 Enter basic deviation "a" of drive pinion (+ or -) under item 2 on data sheet.




38 Add (+) or subtract (-) values of 1 and 2 depending on prefix of value on drive pinion.

39 Insert measuring body of measuring device into rear axle housing and screw-on measuring body (051b).




40 Place magnetic measuring plate (052c) on face of measuring body (051b).




41 Insert dial gauge (052a) into measuring device (052). Push adjusting member (052b) against measuring device and set dial gauge to 0 at 2 mm preload. Tighten clamping screw, while checking 0-position of dial gauge and adjust, if required.




42 Insert measuring device from direction of righthand bore into rear axle housing.


Attention! When introducing measuring device into rear axle housing, make sure that measuring pin of dial gauge is not damaged at bore.


43 Read the difference between preset gauge dimension and face of measuring body with magnetic measuring plate and enter under item 3 into data sheet in plus or minus direction.





Note: The direction plus (+) or minus (-) refers to direction of rotation of dial gauge needle. A deviation from zero position opposite to clockwise direction therefore means minus direction, in clockwise direction plus direction.





44 Add subtotal of values from item 1 and item 2 as well as value from item 3 (+) or subtract (-). This calculated value indicates the thickness of the compensating washer.




45 Remove measuring devices (051, 052, 052c) from rear axle housing.

46 Place compensating washer with measured thickness "S" of washer into rear axle housing (refer to example).


Note: Use hardened compensating washers only; they are available at varying thickness. If required, grind down compensating washer as required.





47 Insert outer races of front and rear tapered roller bearing (43 and 46) into rear axle housing by means of installer (042a-c).




48 Add one contact washer (15) on both sides of spacing sleeve (9) and mount on drive pinion.




49 Insert drive pinion into rear axle housing and support by means of remover and installer (038).




50 Insert inner race of front tapered roller bearing and knock-in with thrust piece (038c).

51 Remove removing and installing tools from rear axle housing.




52 Coat rubber-coated radial sealing ring (42) on circumference with hypoid gear oil or rubber sliding compound "naphtalene H" and push into rear axle housing with thrust piece (038c).

53 Coat running surface for radial sealing ring on universal flange with molybdenum disulfide paste and slip universal flange on drive pinion.





Note: The universal flange can be fastened on drive pinion optionally by means of a crush slot nut (b) which has a groove on circumference, or with a double hex. collar nut (c).

B = drive pinion with groove
b = cruth slot nut
c = double hex. collar nut





54 Screw-on new crush slot nut or double hex. collar nut. Plug holding wrench (015) and slot nut socket or double hex. socket (016) on universal flange and carefully tighten nut until friction torque of 120-140 Ncm on new bearings and of 50-100 Ncm on used bearings has been attained.


Attention! When tightening slot nut or double hex. collar nut, rotate drive pinion several times and by means of light blows against rear axle housing make sure that the rollers of tapered roller bearing are easily entering into bearing races.






55 To check, plug torque meauring instrument (018) with extension on slot nut wrench or double hex. socket (016) and rotate drive pinion.


Note:
The tapered roller bearings of drive pinion must be installed at a given preload. This preload is attained by compression of the spacing sleeve located between the bearing inner race of front tapered roller bearing and drive pinion when the slot nut or collar nut is tightened.

If the friction torque during rotation of drive pinion, that is, if the preload of the tapered roller bearing is too low, slightly retighten slot nut. If the specified friction torque has been exceeded, remove drive pinion again and install a new spacing sleeve. Never reduce friction torque by releasing slot nut or collar nut,since otherwise the preload of the tapered roller bearings would be too low. As a result, the drive pinion would develop play while driving, accompanied by noises in rear axle drive.





56 Place magnetic measuring plate (052c) on face of drive pinion (47) to measure adjusting dimension "A".





57 Insert measuring device (052) with dial gauge for checking adjustment once again from direction of righthand bore into rear axle housing.

On gear set of example named above the dial gauge should indicate a deviation of 0.27 mm from basic dimension in plus-direction, the same dimension which is written on face of drive pinion.

The permissible basic deviation of adjusting dimension "A" should not exceed plus 0.01 and minus 0.02.

If the deviation is higher, grind down installed compensating washer once again or install a new compensating washer of required thickness. But be sure to use a new spacing sleeve for tapered roller bearing.



47 Drive pinion
052 Measuring device
052c Magnetic measuring plate


58 Remove measuring device together with dial gauge and magnetic measuring plate from rear axle housing.


59 Peen crush slot nut or double hex. collar nut with a peening tool into one of the two grooves of drive pinion in such a manner that no gap is provided between groove and locking tab.


Attention! Do not apply any heavy blows in axial direction.

Crush Slot Nut:

Double Hex. Collar Nut:

Dimension for peening tool
a = approx. 8 mm
b = approx. 4 mm