Shim calculation for tooth contact pattern |
Y35.30-0013-06
40 | Pinion shaft |
68 | Pinion head bearing outer race |
69 | Differential lock bush |
Y35.30-0014-06
36 | Retainer wrench 090 589 01 40 00 |
70 | Pinion shaft outer taper roller bearing |
71 | Pinion flange |
Y35.30-0015-06
| Check | ||
1 | Check the crown wheel and the pinion for damages on the teeth like chipping of edges deep scoring, scuffing, excessive wear and improper teeth contac | Replace crown wheel and pinion as a set, if necessary. | |
2 | Check the crown wheel mounting holes and mating threaded holes in the differential housing for any damage | Replace crown wheel and pinion as a set, if necessary. | |
3 | Check the pinion threads for any damage | Replace crown wheel and pinion as a set, if necessary. | |
4 | Check the bearings of crown wheel and pinion for any scoring, pitting, visible indentations and discoloration | Replace the bearing assembly as a set | |
5 | Check differential housing inside for any abnormal wear on the thrust washer seating areas of the sun and star gears | Replace the either thrust washers or the housing based on extent of wear. | |
6 | Check differential gears for any damages to the teeth. Also check the internal splines of side gear and star gear inner bore | Change the set of differential gear, if necessary. | |
7 | Check spider arms for any abnormal wear, scoring and discoloration | Change the set of differential gear, if necessary. | |
8 | Check adjusting ring threads and corresponding threads on the drive head of differential side bearings | Clean the threads and reuse. If the damage is excessive replace drive head housing. | |
9 | Check the bearing seating areas of pinion bearings and differential side bearings for any rotation marks or any other damage in the drive head | Replace drive head housing, if necessary. | |
10 | Check the drive head seating area over the rear axle for any damages and also the seating area of pinion housing seating area | Rectify seating area on the rear axle or drive head as per the requirement. | |
11 | Check the companion flange for any damage at the splines as well deep scoring marks at the oil seal contact area | Replace companion flange, if necessary. | |
| Measure | ||
12 | Shim Calculation for Tooth Contact Pattern | ||
13 | Measure the old shim thickness using micrometer = T = 1.89 mm | Measure the old shim thickness and install the shim with race. | |
14 | Check the PCVN on the old pinion = P = +0.03 mm | ||
15 | Check the new PCVN on the new pinion = N= - 0.07 mm | ||
16 | Required shim (S) = T + P - N | Example 1: Old shim size (T) = 1.89 | |
Above formula can be used in case of crown wheel and pinion change without changing the drive head casing. | |||
17 | Install required shim to the drive head assembly | ||
18 | Install pinion head bearing outer race (68) to drive head housing using special tool drift for pinion side inner race with big handle (or) small handle | Handle | |
Handle | |||
Drift | |||
19 | Install differential lock bush (69) to drive head housing using special tool removal and installation tool | Removal and installation tool | |
20 | Position the drive head housing in horizontal position and install pinion shaft (40) to the drive head housing | ||
21 | Install pinion shaft outer taper roller bearing (70) to pinion shaft using bearing heater | Pinion shaft taper roller bearing heat up to 140º C using bearing heater. | |
22 | Install pinion flange (36) to pinion shaft and lock the pinion flange using special tool retainer wrench (71). Tighten the pinion shaft mounting nut | Install oil seal only after setting the Pre load. | |
Use old flange lock nut to tighten the flange to the pinion for setting Pre-load. | |||
Pinion flange to pinion shaft and lock the pinion flange using special tool retainer wrench | |||
Pinion shaft mounting bolt tighten | |||
Retainer wrench | |||
23 | Tap the pinion shaft using mallet to settle down with the pinion bearing | ||
24 | Rotate the pinion shaft several times in clockwise and anticlockwise direction |
090 589 81 43 00
Removal and installation tool
090 589 87 15 00
Drift
090 589 21 63 00
Handle
090 589 22 63 00
Handle
717 589 00 31 00
Retainer wrench