Reducer 8.6"
1. Install the dial indicator as shown in the figure.
2. Install the indicator foot on the root of the gear driven gear tooth.
3. Adjust the position of the indicator so that the leg is directed in the direction of rotation of the gear and is also perpendicular to the end of the tooth.
4. Preload the indicator leg travel and set the needle to zero.
5. While holding the drive gear, shake the driven gear from stop to stop, record the gap.
6. Repeat the measuring process for eight teeth around the circumference. The difference between the minimum and maximum gap should not exceed 0.05 mm
7. If the gap difference is greater than 0.05 mm, check:
- the presence of scoring on the landing of the driven gear;
- the presence of deformation of the flange of the differential cup;
- uniform tightening of the bolts of the driven gear.
8. If the difference in gap values is normal, then the absolute value of the gap should be in the range of 0.08-0.25 mm, preferably in the range of 0.13-0.18 mm.
Attention:
- Do not reinstall factory cast iron shims, use service washers and spacers instead.
- Install shims of equal thickness on both sides to maintain proper side bearing preload.
- Transferring 0.05mm of shim thickness from one side to the other will change the mesh clearance by approximately 0.03mm.
9. If the engagement clearance is too small:
- A) Turn away bolts of fastening of covers of lateral bearings, mark places of installation of covers.
- b) Remove the gearbox with outer bearing races and shims. Mark the left and right bearing outer races and shims.
- V) Measure the thickness of the shim pack on the left and right sides. Determine the thickness of each washer individually. Take measurements at least at three points along the circumference. Take the arithmetic mean and add the thicknesses of all washers to determine the total thickness of the package.
- G) Assemble a new pack of left side shims, reducing the overall thickness of the pack by the desired amount. For example, to increase the gap by 0.05 mm, decrease the bag thickness by 0.10 mm.
- d) Assemble a new package of right side shims, increasing the overall thickness of the package by the desired amount. For example, to increase the gap by 0.05 mm, increase the bag thickness by 0.10 mm.
10. If the gap is too large, carry out all the operations in step 9, but changing the direction of transferring the thickness of the shims.
11. Install the gearbox with the outer races of the differential side bearings.
12. Install spacer on left side between crankcase and differential.
13. Install the spacer on the right side between the crankcase and differential.
14. Establish between a spacer and an external ring of the left bearing the picked up package of adjusting washers. If necessary, use a special puller.
15. Establish between a spacer and an external ring of the right bearing the picked up package of adjusting washers. If necessary, use a special puller.
16. Install the bearing caps and tighten the mounting bolts. Tightening torque 75 Nm.
17. Recheck the gap in the engagement, if necessary, adjust.
18. After making adjustments, check the position of the tooth contact patch.
Reducer 9.5"
Caution: before adjusting the mesh clearance, adjust the differential side bearing preload.
1. Measure the total torque of the gearbox. Turning moment:
- new bearings 3.9 - 6.2 Nm.
- old bearings 2.8-5.1 Nm.
2. If the turning torque is too low, turn the bearing adjusting nut one slot in the tightening direction until the desired torque is reached.
3. If the turning torque is too high, turn the bearing adjustment nut one slot in the direction of loosening until the required torque is reached.
4. If it is not possible to adjust the total turning torque in this way, check and adjust the driving gear turning torque.
5. Install the dial gauge as shown.
6. Install the indicator foot on the root of the gear driven gear tooth.
7. Adjust the position of the indicator so that the leg is directed in the direction of rotation of the gear and is also perpendicular to the end of the tooth.
8. Preload the indicator leg travel and set the needle to zero.
9. While holding the drive gear, shake the driven gear from stop to stop, record the gap.
10. Repeat the measurement process for eight teeth around the circumference. The difference between the minimum and maximum gap should not exceed 0.05 mm
11. If the gap difference is greater than 0.05 mm, check:
- the presence of scoring on the landing of the driven gear;
- the presence of deformation of the flange of the differential cup;
- uniform tightening of the bolts of the driven gear.
12. If the difference in gap values is normal, then the absolute value of the gap should be within 0.080.25 mm, preferably in the range of 0.13-0.18 mm.
Caution: Transferring 0.05mm of shim thickness from one side to the other will change the mesh clearance by approximately 0.03mm.
13. If the clearance is out of tolerance:
- A) Turn away a bolt of a clamp of a nut of adjustment of the bearing.
- b) Remove the retainer.
- V) Loosen the bearing cover bolts, the bolts do not need to be removed.
- G) Loosen the bearing adjustment nut.
- d) Remove the side bearing shims.
- e) Measure the thickness of the shim. Take measurements at least at three points along the circumference. Determine the arithmetic mean that will give the thickness of the washer.
- and) If the gap is too small, select a thinner washer. For example, to increase the gap by 0.05 mm, the thickness of the washer must be reduced by 0.10 mm.
- h) If the clearance is too large, select a thicker washer. For example, to reduce the gap by 0.05 mm, the thickness of the washer must be increased by 0.10 mm.
- And) Install the adjusting washer.
14. Tighten the bearing adjustment nut until it contacts the bearing outer race.
15. From the position reached, tighten the nut two slots for old bearings or three slots for new bearings.
16. Tighten the bearing cap bolts. Tightening torque 85 Nm.
17. Recheck the size of the gap in the engagement.
18. Install the bearing adjustment nut retainer.
19. Install the retainer bolt. Tightening torque 26 Nm.
20. Check the total turning torque of the gearbox, adjust the torque if necessary, see above.
21. After all adjustments, check the position of the contact patch in the meshing of the gears of the gearbox.