Y35.20-0030-09
Pre - Loading Differential Side Bearings |
1 | Carrier deflection gauge | 5 | Drive head assembly | |
2 | Bearing cap | 6 | Inter axle side gear | |
3 | LHS retainer bolt | 7 | Inter axle assembly | |
4 | RHS retainer bolt |
Y35.20-0031-09
8 | Inter axle assembly sliding fork | 11 | Inter axle lock piston | |
9 | Fork | 12 | Threaded ring | |
10 | Assembly arbor | 13 | Third differential bearing outer race |
Y35.20-0032-09
14 | Input shaft housing cover | 17 | Retainer | |
15 | Coupling flange | 18 | Dummy bolt | |
16 | Dial gauge | 19 | Stopper bolt |
Y35.20-0033-09
15 | Dummy bolt | 22 | Retainer wrench | |
18 | Coupling flange | 23 | Spring | |
20 | Pinion housing cover | 24 | Fork | |
21 | Oil seal installer | 25 | Sliding sleeve |
Y35.20-0034-09
26 | Shim | 29 | Dummy bolt | |
27 | Gasket | 30 | Flange holder | |
28 | Differential lock actuator cover |
| Assemble | ||
1 | Set the crown wheel pinion backlash towards the lower end of value specified. | ||
2 | Now tighten the adjusting rings on the crown wheel teeth side | By using back lash adjuster so that bearing cap on either side slight deflect which is measured using carrier deflection gauge W090589206300 (1). | |
Adjustment device | |||
3 | Ensure the backlash between crown wheel and pinion is with in the limits while the deflection gauge snugly fits in. | This can be achieved by keeping the crown wheel pinion back lash appropriate, such that after tightening the adjusting rings while achieving proper deflection of the bearing caps, crown wheel pinion back lash is also achieved. | |
4 | Install bearing cap (2) mounting bolts | By using 27 mm hexagonal socket and torque wrench. | |
bearing cap mounting bolts | |||
5 | Install both side retainer bolts (3)(4) to threaded rings | Properly install retainer mounting bolts on the bearing cap sides. | |
Retainer bolts to threaded rings | |||
6 | Rotate the drive head assembly (5) flange to upwards. | ||
7 | Apply the oil and install inter axle side gear (6) to drive head housing. | ||
8 | Install inter axle assembly (7) to drive head housing. | ||
9 | Install inter axle assembly sliding fork (8) to drive head housing. | Sliding fork taper surface has to face upwards. | |
10 | Lift the fork (9) and fix sliding sleeve between fork and gear. | ||
11 | Align the fork to correct position | By using drift safety spring and fork aligner and arbor assembly (10). | |
Drift | |||
Assembly arbor | |||
12 | Install spring along with inter axle lock piston (11) to drive head housing using piston compression tool (2). | Avoid reusing inter axle lock piston O-ring and circlip. | |
Thrust device | |||
13 | Install threaded ring (12) to input shaft housing cover and two rotation counter clockwise. | ||
14 | Install the oil seal in the threaded ring and then install the threaded ring into the housing cover. | Apply sealant Loctite 577 to the treads of the threaded ring. | |
15 | Install third differential bearing outer race (13) to third differential cover using special tool | ||
16 | Apply sealant 5900 to input shaft housing and cover. | Loctite 5900 | |
17 | Install input shaft housing cover (14) to drive head housing and tighten the mounting bolts | By using 18mm hexagonal socket and torque wrench. | |
Never apply excess sealant near oil holes and piston area. | |||
input shaft housing cover to drive head housing | |||
18 | Install coupling flange (15) and nut. Hand tighten the nut. Install dial gauge (16) over the pinion shaft threaded end tip vertically for measuring axial play. | ||
19 | Measure inter axle shaft play. | The end play movement need to be 0.05 to 1 mm. | |
If specified value is not obtained, | |||
| |||
Tight/loose the threaded ring to achieve the specified value. | |||
20 | Remove coupling flange and nut. | ||
21 | Install the retainer (17) and tighten the mounting bolts | Retainer bolts to threaded rings | |
22 | Install the dummy bolt (18) to inter axle differential lock hole on housing and slightly tighten. | Ensure inter axle lock is engaged. | |
23 | Install the inter axle lock stopper bolt (19) tight till it touches the inter axle piston. | ||
24 | Loosen the stopper bolt (19) to one revolution and tighten the lock nut. | Loosen the stopper bolt | |
25 | Remove the dummy bolt (18) from housing. | ||
26 | Apply the sealant and install pinion housing cover (20) mounting bolts from drive head housing using 18 mm hexagonal socket and torque wrench. | pinion housing cover mounting bolts from drive head housing | |
27 | Install the oil seal to input shaft using oil seal installer (21) | Insertion tool | |
28 | Lock the coupling flange using retainer wrench (22) | Retainer wrench | |
29 | Install and tighten coupling flange (15) mounting nut (1) to pinion | By using 56 mm hexagonal socket and torque multiplier. | |
Apply sealant loctite 638 to the lock nut. | |||
coupling flange mounting nut to pinion | |||
30 | Install the spring (23) to drive head housing using arbor assembly | Assembly arbor | |
31 | Install fork (24) with sliding sleeve (25) to the drive head assembly. | Check fork and sliding cone for proper fixing. | |
32 | Install piston with shim (26) to drive head assembly. | ||
33 | Install the gasket (27) to the drive head assembly. | ||
34 | Install the differential lock actuator cover (28 and tighten the mounting bolts | | |
35 | Install the dummy bolt (29) to differential lock actuator cover and ensure the differential lock is engaged. | Never remove the special tool dummy bolt till the drive head is install and axle shafts are fixed. | |
Pin | |||
36 | Measure the gap between sliding sleeve and crown wheel. | A. In-engaged position = 1.5 mm. | |
B. In-disengaged position = 2.0 mm. | |||
37 | Lift the drive head from the overhaul stand using flange holder (30) and prepare from installation | Lifting device |
090 589 09 21 00
Adjustment device
090 589 43 31 00
Thrust device
090 589 76 15 00
Drift
090 589 94 15 00
Insertion tool
748 589 02 15 00
Assembly arbor
090 589 07 61 00
Lifting device
717 589 00 31 00
Retainer wrench
090 589 36 15 00
Pin