798646e1

12.4.2. 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 back 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 back bridge.
  3. Mark position of the back 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.
  5. Record a flange not movably by means of a big key of Stillson and give a nut of the leading gear wheel.
  6. By means of a stripper remove a flange from a gear wheel.
  7. By means of the hammer with sliding brisk or the suitable lever take an epiploon from a case.
  8. Smooth out a nest under installation of an epiploon in a case and check its walls for existence of agnails and zadir.
  9. 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.
  10. 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.
  11. Grease with sealant a nut, dress a washer and tighten a nut with effort of 196 ÷ 284 Nanometers - on models Hardtop and Station Wagon and 167 ÷ 245 Nanometers - on Utiliti's (Van) models (Utility) and Cab Chassis.
  12. Connect the driveshaft to a flange (track combination of the tags put in the course of dismantle). Tighten fixing bolts with effort of 93 ÷ 108 Nanometers.
  13. 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

General view of assembly of the main transfer
1 — a case
2 — a flange of the leading gear wheel
3 — a bearing cover
4 — an adjusting nut
5 — a lock tag
6 — the conducted gear wheel

Removal

 PERFORMANCE ORDER

  1. Remove half shafts.
  2. Mark position of the back 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. On the models equipped with the back stabilizer of cross stability give fixing bolts and remove stabilizer bar arms. Lift a bar and tie up it a wire.
  4. Give fixing nuts, remove washers and 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 internal components of the main transfer. At the same time assembly it is necessary to sort and make completely replacement of defective or worn-out parts.
  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 (on models Hardtop and the Versatile person track that laying was established by the party of gray color to the interfaced bridge case surface).
  2. Establish assembly of the main transfer, screw fixing nuts and tighten them with effort of 54 ÷ 64 Nanometers - on models Hardtop and the Versatile person and 27 ÷ 36 Nanometers - on Utiliti's (Van) models and the Mini-truck.
  3. Connect the driveshaft. Track combination of the tags put in the course of dismantle. Tighten fixture with effort of 93 ÷ 108 Nanometers.
  4. Establish to the place of a half shaft. 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. On the models equipped with differential of limited sliding clamp assembly of differential in a vice and insert into side gear wheels of a half shaft. By means of a dynamometer key with a suitable nozzle turn several times one of half shafts, holding at the same time the second not movably and write down the size of resistance to a provorachivaniye. The effort of a provorachivaniye of a half shaft on models Hardtop and the Versatile person has to make 76 ÷ 96 Nanometers, on Utiliti's (Van) models and the Mini-truck - 127 ÷ 226 Nanometers. At an exit of results of measurement out of admissible limits check a condition of frictional disks, and also frictional and spring plates.
  1. 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. Remove lock tags 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 axial assembly 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, remove a washer.
  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. The hammer with soft brisk carefully tap the conducted gear wheel on perimeter for office it from a differential box.
  12. 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. On models with differential of limited sliding (components of differential H260 of limited sliding are shown on an accompanying illustration) during an otdavaniye of fixing screws press the main box of differential.
1 — an adjusting nut
2 — a holder
3 — a cone
4 — the conducted gear wheel
5 — a differential box
6 — a spring plate
7 — a persistent washer
8 — a spring disk
9 — frictional plates
10 — frictional disks
11 — a casing of planetary assembly
12 — a side gear wheel
13 — satellites
14 — axes of satellites
15 — assembly of plates and disks
16 — a differential box cover
  1. Divide a differential box in half and take knot of axes of satellites, satellites, side gear wheels and persistent washers. On models put the removed gear wheels, disks and plates in an organized order with differential of limited sliding, for a guarantee of correctness of installation at assembly you apply identification tags on components.

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.
  8. On models with differential of limited sliding execute the following checks:
    1. Check a condition of components, remove the found agnails and teases by means of a grinding stone.

If defects of the surface of a casing of planetary assembly contacting to a frictional disk are revealed, remove them by means of a grinding stone, then a zapoliruyta a surface with use of thin abrasive paste.

    1. Check disks and plates for existence of signs of wear, agnails and zadir, in case of need make replacement. From semicircular ledges of an agnail can be removed by means of a grinding stone.
  1. Check frictional disks and plates for existence of signs of deformation for what lay them on a flat surface and measure the size of their deformations by the dial measuring instrument (see an accompanying illustration). At excess by result of measurement of the size of 0.08 mm the defective disk / plate is subject to replacement.
  1. Measure thickness of a frictional surface of each of disks/plates in several points by means of a micrometer (see an accompanying illustration). Compare results of measurements to thickness of semicircular ledges near measurement points. If the difference in thickness in any of points exceeds the size of 0.1 mm, replace a worn-out disk / plate.

Assembly

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

 PERFORMANCE ORDER

  1. Grease components with the greasing structure of the required grade.
  2. On the models Hardtop and the Versatile person equipped with differential of limited sliding check an axial side play of frictional disks and plates (see an accompanying illustration):
1 — the surfaces contacting to spring plates
2 — the surfaces contacting to persistent washers
3 — landing sponges
4 — the interfaced surfaces of flanges
    1. Measure by a vernier caliper distance between landing sponges and the differential box surface contacting to a spring plate. Write down result of measurement, then subtract from it distance between landing sponges and the interfaced flange surface. Designate result of subtraction as size C.
    2. Measure distance between the surface contacting to a spring plate and interfaced by a flange surface. Add result of measurement to size C. Designate the sum as size A.

Size A can be received also by assembly of half of a box of differential and measurement by a distance micrometer between the surfaces contacting to spring plates.

    1. Establish knot of axes of satellites between casings of planetary assembly, squeeze casings and measure assembly width a micrometer. Write down result of measurement, having designated it as F.
    2. Collect spring plates from each of the parties and measure thickness of both assemblies by a micrometer.
  1. Collect frictional disks and plates on both sides and measure thickness of both assemblies (see an accompanying illustration).
    1. Put results of two last measurements, designate the sum as size M.
    2. Then calculate the size of an axial side play of assemblies of frictional plates and disks on a formula: An axial side play = And - F - M. If the received result goes beyond an interval of 0.05 ÷ of 0.20 mm, replace frictional plates with plates of the required thickness.

Frictional plates 2.0 and 2.1 mm thick are issued.

    1. Establish persistent washers, casings of planetary assembly, side gear wheels, knot of axes of satellites and satellites in the main box of differential. Do not establish at this stage of a plate and disks.
  1. On models with differential of usual type establish in a box side gear wheels, persistent washers satellites and knot of their axes.
  2. On the models equipped with differential of limited sliding except Utiliti (Van) and the Mini-truck perform the following procedures:
    1. Measure distance between the interfaced surface of a box of differential and the top part of a side gear wheel and a persistent washer. Use the planeness measuring instrument (an edge of a steel ruler) and a vernier caliper. Write down result of measurement, having designated it as And.
    2. 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 the surface of a side gear wheel contacting to a persistent washer and an edge of the measuring instrument. Write down result, having designated it as Century.
    3. For determination of size of a gap of a persistent washer of a side gear wheel subtract value B from value A. If the result of calculation goes beyond an interval of 0.15 ÷ of 0.20 mm, replace persistent washers on new, the required thickness.
  3. On models with differential of usual type gather half of a box, having tracked correctness of combination of the landing tags put in the course of dismantle. Tighten fixing bolts with effort of 64 ÷ 74 Nanometers - on models Hardtop and the Versatile person and 39 ÷ 54 Nanometers - on Utiliti's (Van) models and the Mini-truck.
  4. On models with differential of limited sliding:
    1. Establish side gear wheels, persistent washers, spring and frictional plates and disks in the main half of a box. Track observance of the correct order of installation of components. Spring plates have to be turned by the concave party to a differential box.
    2. Level assemblies of plates with disks and establish casings of planetary assembly and side gear wheels in a box.
    3. Dress satellites and persistent washers on knot of axes of satellites, then bring planetary assembly to a casing. Track that satellites entered gearing with side gear wheels. In case of need install the persistent block.
    4. Establish the remained side gear wheel, a casing of planetary assembly, frictional plates and disks and persistent washers.
    5. Establish a differential box cover, having tracked combination of the landing tags put in the course of dismantle. Densely press half of a box to each other and tighten fixing screws with effort of 8 ÷ 11 Nanometers.
    6. On Utiliti's (Van) models and the Mini-truck measure a gap of a persistent washer of each of side gear wheels for what enter probe edges into an opening to a differential box in the basis of each of side bearings. If the size of a gap goes beyond an interval of 0.05 ÷ of 0.20 mm, replace persistent washers on new, the required thickness.
    7. Clamp assembly of differential in a vice and insert into side gear wheels of a half shaft. By means of a dynamometer key with a suitable nozzle several times turn one of half shafts, holding at the same time the second not movably. The effort of a provorachivaniye on models Hardtop and the Versatile person has to make 76 ÷ 96 Nanometers, or 108 ÷ 137 Nanometers if new frictional disks and plates are established; on Utiliti's (Van) models and the Mini-truck - 127 ÷ 226 Nanometers or 157 ÷ 245 Nanometers, respectively. Otherwise establish frictional plates of other thickness.
  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 in a diagonal order with effort of 132 ÷ 152 Nanometers - on models Hardtop and the Versatile person and 196 ÷ 226 Nanometers - on Utiliti's (Van) models and the Mini-truck, at the same time slightly tapping on their heads with the hammer. There where it is required, bend uvulas of lock plates by means of a center punch.
  8. Grease the outer edge of a new epiploon of the leading gear wheel and a cone of the forward bearing 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 internal 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 - on models Hardtop and the Versatile person and 167 ÷ 245 Nanometers - on Utiliti's (Van) models and the Mini-truck.
  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 on models Hardtop and the Versatile person and 1.5 ÷ 1.7 Nanometers - on Utiliti's (Van) models and the Mini-truck, 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 suitable tool wrap adjusting nuts of side bearings to the moment of the beginning of rotation of cups of bearings.
  1. By means of the dial measuring instrument check a radial side play of the conducted gear wheel of the main transfer (see an accompanying illustration). 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 - on models Hardtop and the Versatile person and 1.7 ÷ 2.5 Nanometers - on Utiliti's (Van) models and the Mini-truck, 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 - on models Hardtop and the Versatile person and 78 ÷ 98 Nanometers - on Utiliti's (Van) models and the Mini-truck.
  3. Establish lock tags 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.
  5. Examine surfaces of teeth of the conducted gear wheel compare a form of a spot of contact with the enclosed help card. 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.
  6. Establish into place assembly of the main transfer and half shaft. Fill in in a case of the back bridge necessary amount of oil of the required grade (see size tables and adjustments at the end of the Management).