Disassemble Rear Final Drive
Drain oil from the final drives and the axle housing.
Loosen hex. head screws, back off and remove the planetary carrier, using back-off screws.
(S) back-off screws (M 16)
Pull stub shaft out of the axle. Carry out steps of figure 1 - 3 on the opposite side.
Loosen lock nuts and separate differential carrier from the axle housing.
Remove lock wire and cotter pins. Screw out adjusting nuts.
Loosen hex. head screws and remove both bearing caps. Lift differential assembly out of the differential carrier housing with a hoist.
Remove lock wire. Loosen hex. head screws and separate both differential case halves from each other. Take the differential gear set with thrust washers out of the case halves.
Pull off tapered roller bearing from the differential case half I + II.
(S) thrust piece
(S) grab sleeve
(S) back-off insert
Loosen locking screws of the bevel gear connection and back off the bevel gear.
Drive out cotter pin, loosen castle nut and pull off flange.
Loosen hex. head screws and remove cover.
Press bevel pinion out of the housing. Remove released inner race of the tapered roller bearing.
Screw out breather. Loosen hex. head screws and back off engine flange.
Lift drive shaft assembly out of the housing.
Pull off tapered roller bearing from the drive shaft.
(S) grab sleeve
(S) back-off insert
Pull off second tapered roller bearing.
(S) grab sleeve
(S) back-off insert
Lift small spur gear slightly. Pull shifter collar with shifter collar sleeve out of the shift fork and remove it from the housing.
Remove small spur gear together with bearing cage, needle bearing and washer out of the housing.
Loosen locknuts and separate spur gear housing from the axle carrier. Mark the housings.
Remove spur gear.
Drive roll pin out.
Loosen both hex. head screws and remove shifter cylinder. Take released shift fork out of the housing. Drive bearing outer races out of the housing, or pull them out with a puller.
Squeeze out circlip. Tap shifter cylinder loose from the piston rod and remove it. Press piston out of the shifter cylinder.
Loosen locknut and remove the components.
Assemble Rear Final Drive
Install piston rings into, resp. upon the pistons.
(S) Installer
Insert O-ring into the groove of the shifter cylinder.
Drive piston firmly against shoulder, using installer.
(S) Installer
Install sleeve. Insert second piston, as illustrated under figure 25.
Introduce piston rod with inserted O-rings.
Install sleeve.
Assemble compression spring and end piece with assembled shaft seal. Fasten by means of circlip. Install locknut.
Torque limit 140 N·m
Introduce, on the opposite side, the compression spring and end piece together with detent block into the shifter cylinder.
Measurement of the Bevel Pinion
Measure dimension A from the middle of the differential bearing to the bearing contact area.
e.g. 179.1 mm
(S) measuring shaft
(S) adapting piece
(S) adapting piece
Determine dimension B (bearing thickness).
e.g. 33.5 mm
Read dimension C pinion distance on the bevel pinion with a depth micrometer.
e.g. 143.9 mm
Install determined thickness washer and bearing outer race into the differential carrier housing.
Introduce spur gear into the transmission housing. Replace gasket. Install eye bolts in spur gear housing and fasten a hoist. Connect spur gear housing with the differential carrier housing. Pay attention to the marking. Fasten by means of locknuts.
Torque limit 95 N·m
Replace spur gear.
Lift inserted spur gear. Slide shifter collar with shifter collar sleeve between both spur gears.
Press heated (135°C maximum) tapered roller bearing upon the bevel pinion.
Assemble thrust washers, install subsequently needle bearing.
Introduce bevel pinion through the installed spur gears and shifter collar sleeve, until contact is obtained.
Fix the bevel pinion axially.
Install heated (135°C maximum) bearing cage firmly against shoulder.
Install the two needle bearings.
Determine dimension B from the flange facing to the inserted washer.
e.g. 35.1 mm
Determine dimension A from the flange facing to the inserted thrust washer.
e.g. 37.4 mm
Determine dimension C frontal difference between inner and out race of the tapered roller bearing.
e.g. 2.5 mm
Select shim which is 0.1 mm thinner, i.e. 4.7 mm in order to reach the specified bearing preload.
Install determined shim. Drive outer race of tapered roller bearing firmly against shoulder. Install heated (135°C maximum) tapered roller bearing.
Press shaft seal into the cover, using driver. Insert O-ring into the groove. Fasten cover at the spur gear housing by means of hex. head screws.
Torque limit 49 N·m
(S) driver
(S) handle
(S) centering sleeve
Replace flange with dust shield and fix it by means of washer and castle nut.
Torque limit 400 N·m
Remove support from the bevel pinion.
Measure rolling resistance. The shaft seal included, the rolling resistance should be 3 - 4 N·m.
If this value has not been found, correct the shim as installed in figure 47.
Insert shift fork into the groove of the shifter collar.
Install shifter cylinder together with gaskets and spacing plate. Fasten provisionally by means of hex. head screws.
Torque limit 49 N·m
Connect piston rod with shift fork by installing the adjusting pin. Actuate shifter device in both directions and check overshifting travel on either side.
If there should be no overshifting travel in one direction, correct by means of a thinner or thicker spacing plate.
Remove adjusting pin. Fasten shift fork finally by installing the roll pins.
Install the heated (135°C maximum) tapered roller bearings upon the drive shaft.
Determine dimension A between flange facing and tapered roller bearing.
e.g. 16.00 mm
Measure dimension B from flange facing to bearing contact area.
e.g. 14.85 mm
Select thickness of shim so that the drive shaft bearing will have an end play of 0.5 - 0.15 mm. In this case, the shim must have a thickness of 1.05 mm.
Install shim, bearing outer race and O-ring into the bearing cover.
Replace bearing cover and fasten it by means of hex. head screws.
Torque limit 120 N·m
Install breather.
Connect crown wheel (bevel gear) and differential case half l by means of locking screws.
Torque limit 160 N·m
Replace heated (135°C maximum) tapered roller bearing.
Insert thrust washer (about 1.8 mm thick).
Pay attention to the grooved pins, if necessary, reset.
Insert side gear and place complete differential gear set with thrust washers upon it.
Check backlash. (Nominal value 0.2 - 0.3 mm). Repeat measuring operation for the differential case half II. If the backlash is beyond the nominal value, correct the corresponding thrust washer (figure 60).
Install heated (135°C maximum) tapered roller bearing upon case half II. Connect differential case half I and case half II by means of hex. head screws.
Pay attention to the marking and the location of the thrust washers.
Torque limit 86 N·m
Secure the screws.
Lift differential complete with bearing outer races into the differential carrier housing.
Install adjusting nuts. Replace bearing caps. Pay attention to the marking. Fasten by means of hex. head screws.
Torque limit 210 N·m
Install adjusting nut on the bevel gear side until a backlash of 0.18 - 0.3 mm has been obtained.
Screw in adjusting nut on the opposite side of the bevel gear until the differential bearings are showing no end play. From this point, tighten the adjusting nut for 2 - 3 notches in order to obtain the specified bearing preload.
Check backlash again and correct if necessary.
Check contact pattern on both tooth flanks. Figure 68 shows the correct contact pattern of the forward flank.
Figure 69 shows the correct contact pattern on the reverse flank.
If the contact pattern should be incorrect, it is absolutely necessary to correct it by the exact adjustment of the bevel pinion distance.
Secure the bearing cap screws. Secure the adjusting nuts.
Disassemble Final Drive Planetary
Loosen hex. head screws, back off and remove the planetary carrier using back-off screws.
(S) back-off screws (M 16)
Remove the snap ring and pull off the sun gear. Remove thrust washer. Pull stub shaft out of the axle.
Unlock slotted nut and remove it.
(S) pin spanner
Remove second slotted nut.
Hold hub tight by means of lifting device. Pull off internal gear.
Pull off hub assembly. Remove tapered roller bearing.
Loosen fastening of the anchor pin.
Remove anchor pin by means of puller and remove the brake shoe. Remove second shoe in the same way.
(S) puller
Loosen hex. head screws and remove brake cylinder.
Loosen allen-head screws. Remove brake anchor plate. Remove hub carrier.
Disassemble planetary drive. Squeeze circlips out. Press planetary shafts out of the planetary carrier.
Remove planetary gears together with thrust washers and bearings.
If necessary, loosen both allen-head screws and separate brake drum from the hub.
Assemble Planetary and Final Drive
Axle is rotated for 90° on the assembly jig (holding fixture).
Cover hub carrier with sealing compound and replace it.
NOTE: Groove for the oil drain goes toward the bottom.
Place brake anchor plate upon it. Pay attention to the location. Fasten by means of allen-head screws.
Torque limit 295 N·m
NOTE: Pay attention to the four shorter screws in the brake cylinder area.
Fasten wheel brake cylinder at the brake anchor plate by means of hex. head screws.
Torque limit 86 N·m
Fasten brake hose nipple.
Connect both brake shoes with return springs, install upon the thrust pins of the brake cylinder and the slack adjuster. Pay attention to a correct contact of the brake shoes.
Drive in anchor pin and fix it by means of locking screw. Pay attention to the overlapping of the blind hole in the pin.
Torque limit 49 N·m
Fasten the brake drum and hub together. Install outer races of the tapered roller bearings into the hub.
(S) driver
(S) handle
Drive seal retainer into the hub until contact is obtained.
(S) driver
(S) handle
Install tapered roller bearing, washer and shaft seal.
Guide hub assembly over the hub carrier, using lifting device. Install subsequently tapered roller bearing.
Slide internal gear upon the splines. Introduce stub shaft.
Install first slotted nut. Tighten until a rolling resistance of the wheel bearing of 11 N·m has been obtained.
Install lock plate and second slotted nut. Tighten second slotted nut.
Torque limit 300 N·m
Check rolling resistance again. Correct rolling resistance 11 - 16 N·m. Secure slotted nut.
Adjust brake until brake is tight, then loosen the corresponding adjusting screw until the brake is free.
Cover flange facing with sealing compound. Fasten a hoist and lift transmission housing assembly into the axle housing. Fasten by means of locknuts.
Torque limit 220 N·m
Introduce stub shaft.
Slide thrust washer and sun gear upon the profile of the stub shaft. Fix by means of the snap ring.
Illustration shows planetary gear, thrust washers, bearing rollers, spacers and shaft with O-ring and inserted snap ring in the correct arrangement.
Guide planetary gear with installed bearing and washers into the planetary carrier. Press shaft with inserted O-ring and snap ring into position. Fix by means of circlip.
| NOTICE |
|---|
Check the groove for the snap ring for wear. Also check the snap rings for wear and stress. Replace with a new one if not of new quality. |
Determine dimension A from flange facing to the face of the inserted detent pin.
e.g. 4.0 mm
Introduce stub shaft until contact is obtained. Measure dimension A from flange facing to the stub shaft face.
e.g. 3.4 mm
The stub shaft must have an end play of 0.3 - 0.6 mm. If necessary, correct by means of shims to be placed under the detent pin.
Install planetary carrier and connect it with the hub by means of hex. head screws.
Torque limit 86 N·m
Fill both final drives and the differential housing with oil, according to the specifications in the Operation and Maintenance Guide.
NOTE: Tighten the nuts that hold the drive wheels to a torque of 550 to 600 N·m