798646e1

12.1.3. Service of assembly of the main transfer

Implementation of the procedures described below will require the following special tools: a wrench of Stillson and a stripper of a flange of the leading gear wheel (for replacement of an epiploon of the leading gear wheel); the listed above tools, plus a stripper for bearings (for dismantling); a press with basic plates, a sensitive dynamometer key of low range of measurement and the dial measuring instrument (for assembly).

Replacement of an epiploon of the leading gear wheel

 PERFORMANCE ORDER

  1. Car front also establish to Poddomkratta it on the props got under frame longerons.
  2. Turn out a drain stopper and lower oil from a case of the forward bridge.
  3. Mark position of the forward driveshaft in relation to a flange of the leading gear wheel, then disconnect the driveshaft from a flange and tie up it aside to a frame longeron by means of a wire piece.
  4. Mark the provision of the leading gear wheel in relation to its flange (the leading gear wheel of the main transfer with the accompanying components is shown on an accompanying illustration).
1 — a washer
2 — a nut
3 — a flange
4 — an epiploon
5 — the bearing
 6 — a holder
7 — adjusting washers
8 — the remote plug
9 — a cup
10 — the leading gear wheel
  1. Record a flange not movably by means of a big key of Stillson and give a nut of the leading gear wheel.
  2. By means of a stripper remove a flange from a gear wheel.
  3. By means of the hammer with sliding brisk or the suitable lever take an epiploon from a case.
  4. Smooth out a nest under installation of an epiploon in a case and check its walls for existence of agnails and zadir.
  5. Fill space between sponges of a new epiploon universal lubricant on a lithium basis. Grease with special lubricant the outer edge of an epiploon and put the last perpendicularly in a case of the main transfer aflush with its end face.
  6. By means of the hammer with soft brisk establish into place the leading gear wheel, having tracked combination of the tags put in the course of dismantle.
  7. Grease with sealant a nut, dress a washer and tighten a nut with effort of 196 ÷ 284 Nanometers.
  8. Connect the driveshaft to a flange (track combination of the tags put in the course of dismantle). Tighten fixing bolts with effort of 78 ÷ 88 Nanometers.
  9. Fill in in a bridge case necessary amount of oil of the required grade (see size tables and adjustments at the end of the Management).

Removal and installation

Removal

 PERFORMANCE ORDER

  1. Remove naves of forward wheels and power shafts.
  2. Mark position of the forward driveshaft in relation to a flange of the leading gear wheel of the main transfer, then disconnect a shaft from a flange. Tie up a shaft aside to a frame element by means of a wire piece.
  3. Give fixing nuts, remove washers and release a brake tube from an arm. Disconnect assembly of the main transfer from a case of the forward bridge. Remove from assembly and you will throw out laying.

Authors of this manual recommend to use for removal the main transfer by the help of the assistant - the weight of assembly is very considerable.

  1. Check a bridge case for existence in it metal sawdust which presence should be regarded as a sign of wear of the main transfer. At the same time assembly it is necessary to sort and make completely replacement of defective or worn-out components.
  2. Smooth out the interfaced surfaces of cases of the bridge and assembly of the main transfer. Track that no garbage got in cases.

Installation

Installation is made upside-down.

 PERFORMANCE ORDER

  1. Establish on a bridge case new laying (the party of gray color to the bridge).
  2. Establish assembly of the main transfer, screw fixing nuts and tighten them with effort of 54 ÷ 64 Nanometers.
    Connect the driveshaft. Track combination of the tags put in the course of dismantle. Tighten fixture with effort of 78 ÷ 88 Nanometers.
  3. Establish into place power shafts and naves of forward wheels. Fill in in a bridge case necessary amount of oil of the required grade (see size tables and adjustments at the end of the Management).

Dismantling

 PERFORMANCE ORDER

  1. Remove assembly of the main transfer. Clamp it in a vice.
  2. Before starting dismantle of assembly execute the following checks:
    1. By means of the dial measuring instrument installed opposite to the interfaced assembly case surface check a beating of the conducted gear wheel of the main transfer. If the result of measurement exceeds value of 0.08 mm whether check foreign particles got between a gear wheel and a box of differential. If those do not manage to be found, replace a differential box.
    2. By means of the dial measuring instrument check a radial side play of the conducted gear wheel in four points. The nominal size of a gap makes 0.15 ÷ of 0.20 mm. At excess by result of measurement of the specified value in any of the checked points (at the admissible size of a beating) replace without fail the conducted and conducting gear wheels, or a differential box (on circumstances).
  3. Apply landing tags on covers of side bearings and surfaces of a case of the main transfer, prilegayemy to them (see an accompanying illustration).
1 — the leading flange
2 — a case
3 — landing tags
4 — the conducted gear wheel
5 — a lock uvula
  1. Remove lock uvulas from covers of side bearings, give fixing bolts and uncover also adjusting nuts.
  2. The wooden lever prop up the conducted gear wheel with assembly of differential, pushing out them from a case of the main transfer. Try not to mix holders of side bearings, - for a guarantee apply on them identification tags.
  3. Mark the provision of an axis of satellites concerning a flange of the leading gear wheel.
  4. Record a flange a big key of Stillson and give a nut of the leading gear wheel.
  5. By means of a stripper remove a flange from the leading gear wheel, then take a gear wheel, the remote plug and adjusting washers from a case (in case of need use the hammer with soft brisk).
  6. By means of the hammer with sliding brisk or the suitable lever take an epiploon from a case, then remove a cone of the external bearing of the leading gear wheel.
  7. Mark the landing provision of the conducted gear wheel on a differential box.
  8. Unbend lock plates (if those are provided) fixing bolts of the conducted gear wheel of the main transfer.
  9. There where it is required, unbend uvulas of lock plates of bolts of fastening of the conducted gear wheel.
  10. Give bolts of fastening of the conducted gear wheel in a diagonal order, remove and you will throw out lock plates (if those are provided).
  11. By means of the hammer with soft brisk carefully tap the conducted gear wheel on perimeter for office it from a differential box.
  12. On models with 2-satellite differential (components are shown on an accompanying illustration) by means of a drift beat out a lock pin of an axis of satellites from the party of the conducted gear wheel turned to a box of differential and remove an axis of satellites, satellites, side gear wheels of differential and persistent washers.
1 — a cover
2 — a lock uvula
3 — a bolt
4 — an adjusting nut
5 — a holder
6 — the bearing
7 — a differential box
8 — the conducted gear wheel
9 — a persistent washer
10 — the satellite
11 — a side gear wheel of differential
12 — an axis of satellites
13 — a pin
  1. On models with 4-satellite differential (see an accompanying illustration) mark the adjusting provision of half of a box of differential (a cover and actually boxes), then give bolts of fastening them to each other. Divide a differential box in half and take knot of axes of satellites, satellites, side gear wheels and persistent washers.
1 — the conducted gear wheel
2 — a differential box cover
3 — the bearing
4 — a holder
5 — an adjusting nut
6 — a cover
7 — a lock uvula
8 — bolts
9 — lock washers
10 — a differential box
11 — a persistent washer
12 — a side gear wheel of differential
13 — satellites
14 — knot of axes of satellites

Cleaning and check of a condition of components

 PERFORMANCE ORDER

  1. Wash out all components in solvent and dry them compressed air.
  2. Check teeth of the conducted and conducting gear wheels for existence of signs of wear, chips and other damages.
  3. Check satellites, side gear wheels of differential, persistent washers and axes of satellites for existence of signs of wear and damages.
  4. Examine a differential box on existence of cracks and other damages.
  5. Check side bearings and their cups for existence of signs of wear, change of coloring and other damages. In case of need remove cones of bearings from a box by means of a stripper.
  6. Check bearings of the leading gear wheel for existence of signs of wear, change of coloring and other damages. In case of need replace bearings for what:
    1. By means of a suitable stripper remove a cone of the internal bearing and the remote plug from the leading gear wheel (if that is established).
    2. As necessary dress the remote plug on the leading gear wheel. Track that the plug was installed by the slanted end to a gear wheel. By means of a press with basic plates establish a new cone of the bearing. Remember that the effort has to be put only to an internal holder of the bearing and until an emphasis of the remote plug in a coat hanger of the leading gear wheel.
    3. By means of a brass drift take cups of bearings from a case of the main transfer.
    4. Carefully install new cups in a case to a firm emphasis them in a coat hanger.
  7. Check the surface of a flange of the leading gear wheel contacting to an epiploon for existence of zadir and signs of wear. In case of need make replacement.

Assembly

Assembly is made as it should be, the return to a dismantle order.

 PERFORMANCE ORDER

  1. Grease components of the required grade with the greasing structure.
  2. On models with 2-satellite differential make assembly of a box:
    1. Establish side gear wheels, persistent washers, satellites and an axis of satellites in a box. Do not establish a lock pin at this stage.
    2. By means of the probe of lezviyny type measure a gap between a persistent washer of a side gear wheel and a wall of a box of differential. If the result of measurement goes beyond an interval of 0.15 ÷ of 0.20 mm, change persistent washers on new, the corresponding thickness.
    3. Level an axis of satellites, having combined lock openings and establish into place a pin before full landing it in a differential box.
    4. Grease with lubricant of the required grade satellites and side gear wheels and check freedom of their rotation.
  3. On models with 4-satellite differential for assembly of a box:
    1. Establish side gear wheels, persistent washers, satellites and knot of axes of satellites in the main half of a box.
    2. Press the planeness measuring instrument (an edge of a steel ruler) to a back surface of a persistent washer of a side gear wheel from the top party of differential and, having blocked gear wheels from rotation, measure distance between the interfaced surface of a box of differential and an edge of the measuring instrument of planeness by means of a vernier caliper. Write down result of measurement (And).
    3. Press the planeness measuring instrument to the interfaced surface of a cover of a box of differential and by means of a vernier caliper measure distance between a contact surface of a persistent washer of a side gear wheel and an edge of the measuring instrument. Write down result (In).
    4. Calculate a gap of a persistent washer of a side gear wheel by subtraction of the size B from the size A. If the result of calculation goes beyond an interval of 0.15 ÷ of 0.20 mm, change persistent washers on new, the required thickness.
    5. Collect with each other two half of a box of differential (track combination of the landing tags put in the course of dismantle). Screw fixing bolts and tighten them with effort of 64 ÷ 74 Nanometers.
    6. Grease with lubricant of the required grade of a gear wheel of differential and persistent washers and check freedom of rotation of gear wheels.
  4. On models with 2-satellite differential grease with the fixing sealant contacting to the conducted gear wheel of the main transfer of a surface of a box of differential.
  5. Establish the conducted gear wheel on a differential box, having used in case of need the hammer with soft brisk. Make sure of combination of the landing tags put in the course of dismantle.
  6. Grease with the fixing sealant fixing bolts of the conducted gear wheel, screw bolts, having established under them new lock plates (if those are provided).
  7. Tighten bolts with effort of 132 ÷ 152 Nanometers in a diagonal order, at the same time slightly tapping on their heads with the hammer. There where it is required bend tags of lock plates by means of a center punch.
  8. Grease the outer edge of a new epiploon with the lubricant of the required grade conducting gear wheels. Fill with universal lubricant on a lithium basis space between epiploon sponges. Install the bearing and an epiploon in a case.
  9. Grease the back bearing with the lubricant of the required grade conducting gear wheels, then establish the leading gear wheel, the remote plug and an adjusting washer in a case. Holding a gear wheel not movably, by means of the hammer with soft brisk begin to knock on it a flange.
  10. Make sure that carvings on the leading gear wheel and a fixing nut are not soiled by lubricant or oil, grease a nut carving with sealant.
  11. Establish a washer, then screw a nut and tighten it with effort of 196 ÷ 284 Nanometers.
  12. Several times turn the leading gear wheel in both directions. Put on on fixing to a hook a dynamometer key and define a gear wheel bearing pretightness. If the size of a pretightness exceeds the limit of 1.3 ÷ 1.6 Nanometers, change an adjusting washer of the bearing for another, the corresponding thickness.
  13. Install cups on cones of side bearings and place assembly of differential with the conducted gear wheel in a case of the main transfer, having tracked that cups of bearings were placed correctly. If old side bearings are used, track that their cups were installed from the same parties, as prior to dismantling.
  14. Screw adjusting nuts of side bearings, having tracked correctness of their nazhivleniye in a carving in a case of the main transfer.
  15. Achieve combination of landing tags of covers of side bearings and a case of the main transfer, establish covers of bearings and by hand tighten bolts of their fastening. If the cover on sits down exactly when pressing by her hand, then the adjusting nut of the bearing is incorrectly leveled concerning a cover.
  16. By means of the dial measuring instrument check a radial side play of the conducted gear wheel of the main transfer. If the result of measurement exceeds 0.02 mm, weaken an adjusting nut from the leading gear wheel and tighten opposite on the same quantity of turns. If the side play appears less than 0.15 mm perform the procedure in the opposite direction.

If the size of an axial side play, is various in various points of the conducted gear wheel, check whether foreign particles got between a gear wheel and a box of differential. If such particles do not manage to be revealed, replace the conducting and conducted gear wheel, or a differential box.

  1. Several times turn the leading gear wheel in both directions, then by means of the dynamometer key which is put on a nut of its fastening check the general pretightness of differential. If the result of measurement goes beyond an interval of 1.8 ÷ 2.5 Nanometers, respectively give, or tighten both adjusting nuts. Having achieved the required value of a pretightness of differential, double-check the size of a radial side play of the conducted gear wheel.
  2. Tighten bolts of fastening of covers of side bearings with effort of 93 ÷ 103 Nanometers.
  3. Establish lock uvulas and strongly tighten bolts of their fastening. Having pressed a plunger of the dial measuring instrument to a basic surface, check the size of a beating of the conducted gear wheel of the main transfer. If the result of measurement exceeds value of 0.8 mm whether remove a gear wheel from a box of differential and check foreign particles got between them.
  4. Grease a surface of teeth of the conducted gear wheel with the Berlin azure, or mix of lead minium with oil, then, having recorded a flange of the leading gear wheel, rotate conducted in both directions.
Contact spot arrangement in gearing of gear wheels of the main transfer (the left column - the party of the forward course, right - the party of a backing):
an and b - the wrong contact, it is necessary to remove the leading gear wheel from conducted, having reduced thickness of an adjusting ring; c and d - the wrong contact, it is necessary to move the leading gear wheel by conducted, having increased thickness of an adjusting ring; e - correct arrangement of a spot of contact.
  1. Examine surfaces of teeth of the conducted gear wheel compare a form of a spot of contact with the enclosed help card (see an accompanying illustration). If the required form of a spot of contact does not manage to be reached, both gear wheels (conducted and conducting) have to be replaced.
  2. Establish assembly of the main transfer, power shafts and naves of forward wheels.