 printable version
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 back 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 rear axle housing.
- Mark the position of the rear 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.
- 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-on models of Hardtop (Hardtop) and Universal (Station Wagon) and 167 ÷ 245 Nm - on models Utility (Van) (Utility) and Mini truck (Cab Chassis ).
- Connect to the flange of the propeller shaft (Track registration deposited in the process of dismantling marks). Tighten the mounting bolts to 93 ÷ 108 Nm.
- Fill the axle housing required amount of oil demanded grade (see. Table sizes and adjustments in the end of this manual).
|
|
Refitting General view of the assembly of the main transfer Withdrawal | - Remove axis.
- Mark the position of the rear 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.
- On models equipped with rear antiroll stability, give fixing bolts and remove the stabilizer bar bracket. Lift the rod and tie it with wire.
- Give fixing nuts, washers and 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 internal components of the main transfer. This assembly must be completely disassembled and replace defective or worn parts.
- Sand mating surfaces axle housing and final drive assembly. Make sure that no debris has not got into the crankcase.
|
|
Setting Installation is in the reverse order. | - Replace the axle housing a new gasket (on models of Hardtop and the Versatile sure that the gasket was installed to the side of the gray housing mating surface of the bridge).
- Install final drive assembly, screw the fixing nuts and tighten them with a force of 54 ÷ 64 Nm - on models of Hardtop and the Versatile and 27 ÷ 36 Nm - on models Utility (Van) and mini-truck.
- Connect the propeller shaft. Ensure registration deposited in the process of dismantling the labels. Tighten fasteners to torque 93 ÷ 108 Nm.
- Replace the axis. Fill the axle housing required amount of oil demanded grade (see. Table sizes and adjustments in the end of this manual).
|
|
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).
- On models equipped with a limited slip differential differential clamp assembly in a vise, and insert into the lateral side gear. Using a torque wrench with an appropriate nozzle rotate several times one of the semi-axes while holding a second and write down the value of fixed resistance turning. The force turning the half-line models of Hardtop and the Versatile should be 76 ÷ 96 Nm on models Utility (Van) and Mini-truck - 127 ÷ 226 Nm. When you exit the measurement of range check the condition of the friction discs and friction plates and spring.
 | - Apply landing marks on the cover side bearings and the adjacent surface of the housing of the main transfer (see. Accompanying illustration).
|
- Remove lock boxes with lids side bearings, 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 axial assembly of the satellites relative to the pinion flange.
- Fix the flange great Stillson wrench and give the pinion nut, remove the washer.
- 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).
- Hammer with soft brisk carefully Tap the driven gear on the perimeter to separate it from the differential housing.
- Mark the installation position of the differential housing halves (of the cover and the box itself), then give the bolts them together. On models with a limited-slip differential (differential components H260 limited slip shown on an accompanying illustration) during the give fixing screws press on the main differential case.
- Divide the differential case half and take out the axes of the satellites, satellites, side gears and thrust washers. On models with a limited-slip differential fold detachable gear, wheels and plates in an organized manner, to ensure proper installation in the assembly apply to components identification tags.
|
|
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.
- On models with a limited-slip differential, check the following:
- Check the condition of the components, remove burrs and burrs discovered using a whetstone.
| If defects are found in contact with the friction surface of the casing of the planetary drive assembly, remove them with a grinding stone, and then polish the surface with a fine abrasive paste. |
- Check the discs and plates for wear, burrs and scoring, in case of need make replacement. With semi-circular projections burrs can be removed with a whetstone.
 | - Check the clutch discs and plates for signs of deformation, which place them on a flat surface and measure the value of the dial strain gauge (see. Accompanying illustration). If you exceed the result of measuring the value of 0.08 mm defective disc / plate should be replaced.
|
 | - Measure the thickness of the friction surface of each of the disks / plates at several locations using a micrometer (cm. Accompanying illustration). Compare results of measurements to the thickness of the semi-circular protrusions near the measuring points. If the difference in thickness at any point exceeds 0.1 mm, replace worn disc / plate.
|
|
|
Assembly Installation is the reverse order of removal. | - Lubricate the lubricating composition of the desired component type.
- On models of Hardtop and the Versatile equipped with limited-slip differential, check the axial play of the friction discs and plates (see. Accompanying illustration):
- Vernier caliper, measure the distance between the landing and the jaws in contact with the spring plate surface of the differential housing. Record the result of the measurement, and then subtracting the distance between the landing sponges and mating surface of the flange. The result of subtracting the label as the value S.
- Measure the distance between the surface in contact with the spring plate and the confronting surface of the flange. Add the measurement result to the value of C. The amount of label as the value A.
| The value of A can also be obtained by assembling the differential housing halves and micrometer measurement distance between the contact surfaces of the spring plates. |
- Install the axes of the satellites between the casing of the planetary assembly, tighten shrouds and measure the width of the assembly of a micrometer. Record the measurement result, designating it as F.
- Assemble the spring plates on each side and measure the thickness of the two assemblies with a micrometer.
 | - Assemble the clutch discs and plates on both sides and measure the thickness of both assemblies (see. Accompanying illustration).
|
- Combine the results of two recent measurements, indicate the amount as the value of M.
- Then calculate the magnitude of the axial backlash assembly friction plates and discs by the formula: A = Axial clearance - F - M. If the result is outside the range 0.05 ÷ 0.20 mm, replace the friction plate on the plate thickness desired.
| Issued friction plate thickness 2.0 and 2.1 mm. |
- Install thrust washers, shrouds planetary assembly side gear assembly axes of satellites and satellites to the main differential case. Do not install at this stage plates and discs.
- On models with conventional differential set in the box side gears, pinion thrust washers and assembly of their axes.
- On models equipped with a limited slip differential, in addition to utilities (Van) and Mini-truck, follow the following procedures:
- Measure the distance between the mating surface of the differential housing and the upper part of the side gear and thrust washer. Take advantage of the flatness measuring instrument (an edge of a steel ruler) and a vernier caliper. Record the measurement result, designating it as 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 thrust washer in contact with the surface of the side gears and the edge of the meter. Record result, designating it as B.
- To determine the size of the gap side gear thrust washer subtract from the value A value of V. If the calculation result is outside the range 0.15 ÷ 0.20 mm, replace the thrust washers for new, desired thickness.
- On models with conventional differential gather together half of the box, having tracked correctness of combination applied in the process of dismantling the landing labels. Tighten the mounting bolts to 64 ÷ 74 Nm - on models of Hardtop and the Versatile and 39 ÷ 54 Nm - on models Utility (Van) and mini-truck.
- On models with a limited-slip differential:
- Set in the main half of the box side gears, thrust washers, springs and friction plates and discs. Ensure compliance with the correct order of installation components. Spring plate must be inverted to a concave side of the differential housing.
- Align the plate assembly disk and set box covers planetary assembly and side gears.
- Dress on the node axes of satellites satellites and thrust washers, then start the planetary assembly in the casing. Make sure that the satellite went into engagement with the side gears. If necessary, set the stop block.
- Install the remaining side gear casing of the planetary assembly, friction plates and discs, and thrust washers.
- Replace the cover of the differential housing, tracked by combining supported during dismantling landing labels. Firmly press box half to each other and tighten the mounting bolts to 8 ÷ 11 Nm.
- On models of utilities (Van) and Mini-truck measure a backlash thrust washer each of the side gears, by entering the blade of the probe into the hole in the bottom of the differential housing each of the side bearings. If the size of the gap outside the range 0.05 ÷ 0.20 mm, replace the thrust washers on the new desired thickness.
- Hold differential assembly in a vise, and insert into the lateral side gear. Using a torque wrench with an appropriate nozzle rotate several times one of the semi-axes while holding a second still. The force turning on models of Hardtop and the Versatile should reach 76 ÷ 96 Nm or 108 ÷ 137 Nm, if new clutch discs and plates; on models of utilities (Van) and Mini-truck - 127 ÷ 226 Nm or 157 ÷ 245 Nm, respectively. Otherwise, set the other friction plate thickness.
- 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 the bolts in diagonal order to force 132 ÷ 152 Nm - on models of Hardtop and the Versatile and 196 ÷ 226 Nm - on models Utility (Van) and Mini-truck, while tapping lightly on their heads with a hammer. Where required, bend the tabs lock plate using a center punch.
- Grease the outer edge of a new oil seal pinion front bearing cone and 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 inner 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 - on models of Hardtop and the Versatile and 167 ÷ 245 Nm - on models Utility (Van) and mini-truck.
- 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 on models of Hardtop and the Versatile and 1.5 ÷ 1.7 Nm - on models Utility (Van) and Mini-truck, 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.
- With the help of a suitable tool tighten the adjusting nuts of the side bearing to the start of the rotation of the bearing cups.
 | - Using a dial gauge, check radial play ring gear (see. Accompanying illustration). 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 - on models of Hardtop and the Versatile and 1.7 ÷ 2.5 Nm - on models Utility (Van) and Mini-truck, 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 - on models of Hardtop and the Versatile and 78 ÷ 98 Nm - on models Utility (Van) and mini-truck.
- Install the lock boxes, and firmly 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.
- Inspect the surface of the teeth of the driven gear compare the shape of the contact patch with the attached reference card. If the desired shape of the contact can not be reached, the two gears (master and slave) must be replaced.
- Replace the final drive assembly and the axis. Fill the rear axle housing required amount of oil demanded grade (see. Table sizes and adjustments in the end of this manual).
|
|
|
