Installing drive pinion with bearing in rear axle housing

AR35.30-D-4815-09TSR

Installing drive pinion with bearing in rear axle housing

Rear axle

741.421/422/423/453/454/455/456 in model 907

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.421/422/453/454/455/456

Rear axle 741.423

BE35.30-N-1001-01B

Friction torque of drive pinion bearing

with radial shaft sealing ring

Nm

1,85...3,94

1,85...3,94

without radial shaft sealing ring

Nm

1,65...3,74

1,65...3,74

 Rear axle shaft

Number

Designation

Rear axle 741.421/423

Rear axle 741.422/453/454/455/456

BA35.30-N-1005-01A

Nut, joint flange to drive pinion

200

200

1

Insert determined spacer disk into mounting hole for inner bearing shell.

 The chamfered side of the spacer disk must face toward the mounting hole.

2

Insert inner bearing shell into rear axle housing (1).

 Align inner bearing shell parallel to mounting hole. New inner bearing shells may not be oiled or cleaned, and they must be installed in the supplied condition.

3

Draw inner bearing shell into rear axle housing (1) using  insertion device (01).

4

Check contact surface of inner bearing shell on rear axle housing (1) using feeler gauge (thickness 0.05 mm).

 The inner bearing shell must be fitted flush to the mounting hole in the rear axle housing (1).

5

Insert drive pinion (2) into rear axle housing (1).

6

 Attach installer tool (04) to rear axle housing (1) and position spindle at centering bore of drive pinion (2).

7

Fix drive pinion (2) with spindle into place in inner bearing shell.

8

Prepare threaded rod (05), pinion support (06) and housing support (07) from  measuring device.

9

Attach threaded rod (05) to pinion support (06).

10

Screw pinion support (06) with threaded rod (05) finger-tight onto drive pinion (2).

11

Install housing support (07) in rear axle housing (1).

12

Prepare dial indicator (08) and punch (09) from  measuring device.

13

Install outer bearing shell (3).

14

Insert dial indicator (08) into punch (09) and set a pretension of 3.5 mm.

15

Position punch (09) with dial indicator (08) onto tapered roller bearing (4) and calibrate dial indicator (08) to zero.

 The calibration procedure for the dial indicator (08) must be made on the measuring plate.

16

Prepare support disk (010) from  measuring device.

17

Position punch (09) with dial indicator (08) and tapered roller bearing (4) on pinion support (06).

 Make sure that the dowel pin (5) of the pinion support (06) engages in the bore (6) of the punch (09).

18

Insert support disk (010).

19

Prepare force applicator (011) with toggle (012) from  measuring device.

20

Screw force applicator (011) with spring onto threaded rod (05).

 The toggle (012) must be in the uppermost position during assembly, to prevent any spring pretension.

 Drive pinion (2) must be held securely when screwing on force applicator (011).

21

Turn toggle (012) with zero clearance up against spring.

 Note the deflection of the number value, caused by rotation of the toggle (012) on the dial indicator (08). The deflection intensity initially stays at a constant level and drops off suddenly after several turns. At this particular moment, the free play of the spring is reached and the toggle (012) may then no longer be turned.

 Also ensure free play through upward and downward movement of spring.

22

Turn toggle (012) through 14 turns clockwise.

23

Turn entire body at hexagon (arrow a) 10 turns clockwise.

 This serves to ensure that the outer bearing shell (3) is correctly seated.

24

Turn toggle (012) through another 14 turns clockwise.

25

Determine each highest and lowest measurement value by turning entire body.

 To do so, red off measurement value on dial indicator (08) and note down.

26

Calculate mean value.

 The mean value is determined by adding the highest and lowest measurement value and then dividing their sum by two.

27

Calculate thickness of shim (7).

 The shim thickness is calculated by adding the specified correction value and the mean value.
Example
(Highest measurement value + Lowest measurement value) : 2 = Mean value
(2.515 mm + 2.505 mm): 2 = 2.51 mm
Mean value + Correction value = Shim thickness
2.51 mm + 0.07 mm = 2.58 mm (tolerance 5 μm)

28

Remove all special tools.

29

Remove drive pinion (2).

30

Install outer bearing shell (3) using a suitable drift.

 Align the outer bearing shell (3) parallel to the mounting hole. The new outer bearing shell (3) may not be oiled or cleaned and must be installed in the supplied condition.

31

Install drive pinion (2) and fix in place with spindle.

 To do so, install the drive pinion (2) without zero clearance.

32

Insert determined shim (7).

33

Insert tapered roller bearing (4).

34

Drive in old drive flange (8) without radial shaft sealing ring using suitable sleeve and rubber hammer until collar nut can be screwed on.

35

Screw on collar nut by hand.

36

Mount  retainer wrench (013) onto old drive flange (8).

37

Tighten collar nut to specified torque   .

38

Turn old drive flange (8) by 5 turns clockwise, then retighten again to torque   .

39

Remove  retainer wrench (013).

40

Determine friction value with  torque meter (014)  and compare with specified value.

If the measured value is outside the tolerance range,



repeat entire procedure.

41

Remove old drive flange (8).

If the measured value is inside the tolerance range.