- with final drive removed - The number of teeth on the gears built in is shown on the casing. |  |
Take off driving flange using pull clamp No. 7011-2. |  |
Remove cap. Take out complete differential casing. Note when assembling: Before assembly, insert spacer tube into differential casing. |  |
Take off ring. Note when assembling: Secure collar nut in driving flange by tightening the lock ring in the groove. |  |
Counterlock driving flange by means of clamp tool No. 7012 and loosen collar nut. |  |
Press out drive pinion. |  |
Remove shaft packing ring. Take out taper roller bearing. |  |
Pull out the outer bearing rings for the drive pinion by means of pull tool No. 6053. 1 outer bearing ring (front) 2 expander element 3 stop disc 4 draw-out cap 5 thrust bolt |  |
1 Rear bearing outer race 2 Expander 3 Limit plate 4 Extractor cone 5 Thrust bolt |  |
Pulling in bearing outer races. Installation of the rear bearing outer race is shown. 1 Bearing outer race 2 Drawing-in plate, rear 3 Nut 4 Drawing-in plate, front 5 Thrust bolt |  |
The cownwheel and pinion have been matched on special machines for maximum operating silence. The matching number (p) has been electrically inscribed on crownwheel and pinion. Crownwheel and pinions with differing matching numbers (P) should never be assembled together. The figure (e) accompanied by a + or - sign is the variation from the basic setting dimension E in hundredths of a mm and is required for ascertaining the thickness of shims X. e + = add to E e - = subtract from E |  |
Downwheel and pinions sets have Klingelnberg (Palloid) and Gleason tooth profiles. With the Klingelnberg tooth profile the tooth spine on the drive pinion is the same both outside and inside. Klingelnberg sets are stamped with the letter K on both crownwheel and pinion. |  |
With the Gleason tooth profile the tooth spine on the crownwheel is wider on the outside than on the inside. Gleason sets are marked H or F on crownwheel and pinion. |  |
Press on taper roller bearing and measuring plate A - 4.05 mm (1.594") thick. To facilitate fitting, coat bearing inner race with grease. Note! Installing position of plate A: chamfered inside diameter should face towards drive pinion. |  |
Press front taper roller bearing on to drive pinion with insertion tool 6057 and Kukko 22!1. |  |
Fit driving flange without shaft sealing ring. |  |
Set drive pinion taper roller bearing to 22 ± 1 cmkp. |  |
Asceration C= thickness of measuring block. Place measuring block on front face of the drive pinion. |  |
Set dial gauge to 0 at 4 mm (0.157") depression. Note! The dial gauge can also be set for any other depression. Determine D. D is calculated from the diameter shown on the gauge divided by 2. e. g. 40.0 mm (1.574") ÷ 2 = 20.0 mm (0.787"). |  |
Insert gauge 6954 into housing. Take reading from dial gauge B and determine Y. Taking into account the variation e from the basic dimension E determine thickness of shim X. E Klingelnberg tooth profile 59.0 mm (2.322") E Gleason tooth profile 61.85 mm (3,086"). |  |
Example 1 1. E 59.00 mm (2.323") e + 0.15 mm (0.006") ------------------------------------------ E theoretical 59.15 mm(2.328") ------------------------------------------ 2. C 38.00 mm(1.496") + D : 2 20.00 mm(0.787") ------------------------------------------- 58.00 mm(2.283") -------------------------------------------- 3. Depression dial gauge 4.00 mm(0.157") Less measured value B 3.12 mm (0.123") ------------------------------------------- Clearance Y 0.88 mm(0.034") 4. Sum C, D 58.00 mm(2.283") + Y 0.88 mm(0.346") ----------------------------------------- E actual 58.88 mm(2.629") ----------------------------------------- 5. E theorectial 59.15 mm(2.328") E actual 58.88 mm(2.629") ---------------------------------------- a 0.27 mm(0.106") ---------------------------------------- 6. Measuring plate A 4.05 mm(0.159") - a 0.27 mm(0.10") ----------------------------------------- Shim X 3.78 mm(0.149") Example II 1. E 61.85 mm(2.434") e - 0.12 mm(0.004") -------------------------------------- E theoretical 61.73 mm(2.430") ---------------------------------------- 2. C 38.00 mm(1.496") + D : 2 20.00 mm(0.787") ---------------------------------------- 58.00 mm(2.283") ---------------------------------------- 3. Depression dial gauge 7.00 mm(0.275") Less measured value B 3.12 mm(0.122") --------------------------------------- Clearance Y 3.88 mm (0.152") ---------------------------------------- 4 Sum C, D 58.00 mm(2.283") + Y 3.88 mm(0.152") -------------------------------------------- E actual 61.88 mm(2.436") -------------------------------------------- 5. E theoretical 61.73 mm(2.430") E actual 61.88 mm(2.436") --------------------------------------- a 0,15 mm (0.006") --------------------------------------- 6. Measuring plate A 4.05 mm(0.159") + a 0.15 mm(0.006") ------------------------------------- Shim X 4.20 mm (0.165") -------------------------------------- If E theoretical is greater than E actual, a'should be subtracted from the measuring plate A. If E theoretical is less than E actual, a´should be added to the measuring plate A. Permissible thickness tolerance of shim X with Klingelberg tooth profile ± 0.03 mm (0.0012") with Gleason tooth profile ± 0.04 mm (0.0016"). |  |
Remove drive pinion. Pull off taper roller bearing with Rollex HM 89449. |  |
Fit drive pinion with shim X as calculated and a new clamp bush (1). Note! The chamfered inside diameter of the shim X should face towards the drive pinion. |  |
Pack shaft sealing ring with grease and fit flush. Secure driving flange with flanged nut. Set drive taper roller bearing to 22 ± 1 cmkp + 4 cmkp for the shaft sealing ring. If the coefficient of friction is exceeded, the clamp bush must be renewed and the measuring procedure repeated. |  |
Release crownwheel from differential housing. Fitting instruction: Fit crownwheel cold. Use Loctite AVV when fitting bolts. |  |
Extract taper roller bearing with Rollex LM 503349. Fitting instruction: press on taper roller bearing cold. |  |
Pull bearing race out of housing with extractor tool 6053. Note! Mark shim. |  |
Pull bearing race out of cap. Note! Mark shim. Extract O ring. |  |
If the new crownwheel and pinion set has the same tooth profile as the one removed, the old shims can be fitted. This will facilitate rapid checking of coefficient of friction, tooth flank play and tooth contact characteristics. If a crownwheel and pinion set with a different tooth profile is fitted, for basic setting with the Gleason tooth profile shims (1) of thickness 1.40-1.70 mm (0.551-0.669") should be used and with the Klingelnberg tooth profile a thickness of 2.20-2.40 mm (0.866-0.944"). |  |
Fit bearing outer race (1) and one shim (2) in the cover with extractor tool 6053. |  |
Turn the drive flange fixing bolt (1) against the differential pinion shaft. Fit differential housing without crownwheel. |  |
Tighten cover fixing bolt uniformly at 2.0 ± 0.5 mkp (1.45 ± 36.2 Ib/ft.) and measure coefficient of friction. Note !The coefficient of friction for new bearings is 14-16 cmkp. If the coefficient of friction measured is below 14 cmkp a thicker shim must be fitted under the bearing outer race in the cover. Determine gap and subtract from the shim in the cover. Example: Shim is 2.20 mm (0.866"). Gap 0.30 mm (0.012") -------------------------------------------------------------------- Shim should be 1.90 mm (0.748") -------------------------------------------------------------------- |  |
Fit shim thus calculated. Fit cover and again check coefficient of friction. Fix crownwheel in differential housing. Insert screws using Loctite AVV and tighten at recommended torque. Fit crownwheel. Remove breather housing (1). |  |
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To take a tooth contact pattern, smear the crownwheel with engineer's blue, rotate several times in both directions and brake with a piece of hardwood. |  |
The torsional flank play and the contact pattern will be altered by shims 1 and 2. Shims 1 and 2 should be changed until torsional flank play and contact pattern are correct. Alteration of shim thickness by 0.10 mm (0.004") will produce a change in torsional flank play of approximately 0.05 mm (0.002"). Note! On no account should the total thickness of shims 1 and 2 be changed. |  |
Basis principles to be observed when adjusting contact pattern Gleason contact pattern: A Correct contact pattern without load. A1 When subject to load, the contact pattern is moved somewhat to the outside. A change in the position of the crown wheel will mainly influence flank clearance, although it also changes the contact pattern in the longitudinal direction of the serration. A change in the position of the bevel drive pinion will move the contact pattern along the serration peaks, whereas flank clearance is hardly changed. In this context, please note the four basic false contact patterns, which, although they usually occur in a combined form, are of importance in view of adjustment work. 1. A high and narrow contact pattern on the crown wheel. If this is the case, push the bevel drive pinion towards the crown wheel axle and, if necessary, correct torsional backlash by pushing the crown wheel away from the bevel drive pinion. 2. A deep and narrow contact pattern on the crown wheel. If this is the case, push the bevel drive pinion away drom the crown wheel axle and, if necessary, correct torsional backlash by moving the crown wheel in closer. 3. A short contact pattern at the small end of the crown wheel gears. If this is the case, push the crown wheel away from the bevel drive pinion and, if necessary, push the bevel drive pinion towards the crown wheel axle. 4. A short contact pattern at the large end of the crown wheel gears. If this is the case, push the crown wheel towards the bevel drive pinion and, if necessary, push the bevel drive pinion away from the crown wheel axle. |  |
Kingelnberg contact pattern: The contact pattern must be on the front and rear side of the bevel drive pinion, at approximately the middle of the gear with some space left free at the left, right, top and bottom. B Contact pattern without load. C Contact pattern with load. D By fitting a thicker space disc "X" behind the bevel drive pinion, it is possible to move the contact pattern on the front side of the gears towards the larger bevel drive pinion diameter, whereas on the rear side of the gears ist will move towards the smaller bevel drive pinion diameter. For further possibilities of changing contact pattern, see illustration (E). |  |
Adjustment of contact pettern. |  |
¹) See Technical Data