Replace ring gear on flywheel

AR03.30-B-8312TC

Replace ring gear on flywheel

20.12.2017

Engine

457.9 in model 934, 958.4

Engine

460.984 in model 934, 938.142

1

Rack

2

Engine flywheel

A

Hole (to house the screw for the clutch pressure plate)

B

Internal diameter of the rack and diameter of the steering wheel for housing of the rack



Remove

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

1

Remove the engine flywheel (2)

AR03.30-B-8002TC

2

Heat the rack (1) quickly with a welding burner and remove it from the engine flywheel (2) with a suitable chuck

 Pave the engine flywheel (2).



Measure

3

Measure the internal diameter of the rack and the diameter of the wheel for housing of the rack (B) in the engine flywheel (2) and calculate the overlap between the rack (1) and the engine flywheel (2)

 If necessary, replace the engine flywheel (2) or adapt the diameter of the wheel for housing of the rack (1) to reprocess the following allowed variation and choose a new rack (1) with corresponding allowed variation.

Flywheel outside diameter

*BE03.30-B-1001-03H

Ring gear internal diameter

*BE03.30-B-1012-03H

Interference between the ring gear and steering wheel

*BE03.30-B-1013-03H



Install

4

Heat the new rack (1)

 The correct assembly temperature is reached when the tempering color of the toothed rack (1) is light yellow.

Ring gear mounting temperature

*BE03.30-B-1017-03H

5

Place the rack (1) up to the installation surface on the engine flywheel (2)

 Let the rack (1) cool down for at least 2 minutes and lower the rack (1) by using a brass chuck.

6

Fix centerings in the rack (1) by the holes (A)

 Use a drill with a diameter of 11,0 mm. The centerings are required to pre-drill the diameters of the central hole.

7

Pre-drill the diameters of the central hole for the nut in the rack (1)

 Use a drill with a diameter of 4.5 mm.

8

Drill the diameters of the central hole for the nut in the rack (1) up to the edge

 Use a drill with a diameter of 8.5 mm.

9

Turn the engine flywheel (2) and correct the diameters of the central hole in the rack (1)

10

Open nuts at every diameter of the central hole in the rack (1)

 Tool set / male (M10).

11

Assemble the engine flywheel (2)

AR03.30-B-8002TC

Engine flywheel

Number

Designation

Engine 457.9, 460.984

BE03.30-B-1001-03H

Flywheel outside diameter

mm

486,6...487,4

Engine flywheel

Number

Designation

Engine 457.9, 460.984

BE03.30-B-1012-03H

Ring gear internal diameter

mm

432,000...432,155

Engine flywheel

Number

Designation

Engine 457.9, 460.984

BE03.30-B-1013-03H

Interference between the ring gear and steering wheel

mm

0,335...0,645

Engine flywheel

Number

Designation

Engine 457.9, 460.984

BE03.30-B-1017-03H

Ring gear mounting temperature

°C

200...230