Manual Eixos Difer Dupla Veloc 2012-06 ING

MANUAL DE MANTENIMIENTO

Diferenciales Doble Velocidad

MS - 220

MS - 230

MS - 240

Edición octubre/11

Index

1 - Important information ......................................................................................... 03

2 - Introduction ........................................................................................................ 04

3 - Exploded View ................................................................................................... 06

4 - Identification....................................................................................................... 08

5 - Disassembling ................................................................................................... 09

6 - Cleaning – Drying – Inspection – Storage ......................................................... 18

7 - Maintenance / Restoration ................................................................................. 21

8 - Liquid Adhesive ................................................................................................. 22

9 - Chemical Gasket ............................................................................................... 23

10 - Reassembly ....................................................................................................... 24

11 - Pinion Bearings.................................................................................................. 34

12 - Pinion Installation............................................................................................... 38

13 - Satellite System / Planetary ............................................................................... 44

14 - Bearing Cage Bearings...................................................................................... 45

15 - Backlash Gear ................................................................................................... 46

16 - Tooth Contact, Ring Gear and Pinion ................................................................ 47

17 - Lubrication….......................................................................................................50

19 - Tightening Torques ............................................................................................ 52

20 - Instruction .......................................................................................................... 53

MAINTENANCE MANUAL

Axel Changes Updating

In order to keep the maintenance manual up to date, at every modification in the axis, a Technical Instruction will be issued with the data and the implications resulting from these changes.

At the bottom of each page of this manual there is a designated area to record the number of each Technical Instruction which involves any possible changes on that page as the example below.

Safety

It is extremely important wearing safety equipments during shaft maintenance.

• When using a hammer or performing any operation which involves impact, always use safety eyes protection.

• When handling hot parts or sharp corners, always use protection gloves.

Important information

MAINTENANCE MANUAL 3

Introduction

The differential planetary are two-speed drive units with planetary reduction, which have the following features:

A. Generoid System Ring Gear and Pinion;

B. Pinion with rod over two tapered roller bearings, which absorb the axial and radial loads, and a cylindrical roller bearing at the top of the head, which absorbs the radial loads;

C. Ring Gear and Bearing Cage set, mounted on tapered roller bearings;

D. Planetary and Satellites with straight conical teeth;

E. Secondary reduction provided by a Spur

Gear Planetary system, located under the

Hipoidal Ring Gear.

First Reduction – High Speed

At high speed, the sun gear is engaged with the bearing cage, which blocks the functioning of the planetary system gears.

With the planetary gear locked, the motion effort of the Ring Gear and Pinion pair is transmitted directly to the gears of the differential system

(satellites and planetary).

Thus, the drive unit will function as a simple reduction drive system, allowing the vehicle to develop higher velocities.

4 MAINTENANCE MANUAL

Second Reduction – Low Speed

At low speed, the Sun gear is engaged to the blocking plate.

Thus, the drive unit will function as a double-

-reduction drive system, allowing increasing the traction capacity of the vehicle.

The speed change is effected by a mechanism

(electrical, air or vacuum type) mounted on their differential control unit installed in the cabin of the vehicle. Turning the mechanism on, the sun gear is displaced from its previous position and engages with the locking plate, thereby releasing the operation of the gears of the planetary system.

First Reduction – High Speed

Introduction


Exploded view


Exploded view

SERIES 220 / 230 / 240

ITEM DESCRIPTION

8

9

10

11

12

13

1 Differential Case

2 Capscrew (Differential Bearing

Cap)

3 Washer

4

5

Roll Pin

Satellite Box (Half planetary)

6 Satellite Box (Simple Half)

7 Satellite

Satellite Thrust Washer

Differential Spider

Planetary (Short Hub)

Planetary (Long Hub)

Planetary Thrust Washer

Fastener (Satellite Case Assembly)

21

22

23

24

25

26

27

14

15

Planetary Gear Shaft

Thrust Washer

16 Planetary Gear

17 Pin

18

19

20

Satellite Case Thrust Washer

Case Half - Flange

Case Half - Simple

Fasteners – Bearing Cage

Bearing Cone (Case Half Flange)

Bearing Cone (Case Half Simple)

Bearing Cup (Case Half Flange)

Bearing Cup (Case Half Simple)

LH Adjustment Ring

RH Adjustment Ring

28

29

30

31

32

Cotter Pin

Lock Screw

Sun Gear

Clutch Plate

Studs (Clutch Plate)

ITEM DESCRIPTION

40

41

42

43

44

45

33 Tapered Washer

34 Nut

35 Shift Fork

36

37

Shift Shaft

Lock Plate Capscrews

38 Plug

39 Ring Gear and Pinion

Spigot Bearing

Snap Ring

Adjusting Shims (Bearing Cage)

Bearing Cage (Drive Pinion)

Bearing Cup (Pinion Inner)

Bearing Cup (Outer)

46

47

48

49

50

51

52

Bearing Cone (Outer)

Adjusting Shim (Pinion Bearing)

Bearing Cone (Inner)

Universal Joint Fork

Dust Deflector

Pinion, Oil Seal

Washer

53

54

55

Pinion, Nut

Screws (Bearing Cage)

Washer

56 Ring Gear Thrust Screw

57 Nut

58 Diaphragm

59 Stud (Mechanism Holder)

60 Washer

61 Nut

62 Speed Changing Mechanism

63

64

Roller Pins Spacer

Roller Pins


Identification

The unit presents identification plates, which are marked with the basic specifications of product.

Before starting the service operations, identify the unit to be repaired, referring to the nameplate affixed to the housing and differential housing. This information will allow a correct identification of the replacement parts desired, thus allowing the execution of a service operation more quickly and accurately.

Model (Model)

Cust.No. (Customer number)

Part.No. (Product number)

Ratio

Serie No.

Date

(Differential Reductions)

(Serial number)

(Manufacturing Date)

IDENTIFICATION PLATE

IDENTIFICATION PLATE

AXEL ASSEMBLY IDENTICATION PLATE


Disassembly

Before starting the service operations, identify the unit to be repaired, referring to the nameplate affixed to the housing and differential housing.

• Remove the drain plug, located in the inner face of the case bowl and drain the entire oil in. (Figure 2).

• Loose the nuts, locking washers and tapered washers from the semi-axes fastening studs.

IMPORTANT: To remove tapered washer, support a brass bar (diam. 38 mm) in the existing depression in the center of the semi-

-axle flange and hit it with a brass hammer or use an auxiliary nut, hammering the hexagonal part of the nut (Figure 4).

Plug

Figure 2

CAUTION:

1. DO NOT HIT DIRECTLY ON THE SEMI-

-AXLE.

2. DO NOT INSERT WEDGE OR CHISEL

BETWEEN THE SEMI-AXLE AND THE

WHEEL HUB, TO AVOID UNRECOVERA-

BLE DAMAGE IN THESE PARTS.

• Remove semi-axles.

• Disconnect the Driveshaft.


Figure 3

Figure 4

9

Disassembly

Gear Shift Mechanism Disassembling

A. Uncouple the mechanism’s actuation line;

B. Remove the nuts and washers from the gear shift mechanism fasteners;

C. Remove the mechanism (Figure 5);

WARNING:

There may be a little tension in the spring of the mechanism a bit difficult to remove, but this is normal.

D. If there is a diaphragm installed, remove it manually. If replacement is necessary, discard the diaphragm and the retention spring (Figure 6).

Differential Removing

A. Manually displace the gear shift mechanism

(in the opposite direction to the differential) until it is in the low speed position (LS). This operation tends to eliminate the interference between the sun gear and the mouth of the housing, helping to make easier disassemble the differential;

B. Remove the nuts and washers from the differential fastening studs and screws;

C. Disassemble the differential from the housing using appropriate supports and a hydraulic jack. (Figure 7);

Important:

1. When necessary to use extracting screws, the differential housing flange has threaded holes (2 for the model 220 and 3 for models

230/240) for this purpose. You can use the same screws that fix the differential in this operation.

2. Hit firmly, when necessary, using a plastic hammer to loosen the differential form the effect of the chemical gasket.

D. Install the unit in a suitable support

(Figure 8).

Figure 5

Figure 7

Figure 6


Disassembly

Figure 8 Figure 10

Speed Shift Removing

A. Hit the caps and the hinge pin of the fork, using a brass pointer and a plastic hammer strokes (Figure 9);

C. To remove the locking plate, loosen its fasteners.

WARNING:

The pin should be removed by the upper side of the differential, because its housing is scaled.

B. Simultaneously remove the fork and the

Sun gear (Figure 10);

CAUTION:

DO NOT HAMMER THE PLATE DIRECTLY

OR INSERT CHISEL AND WEDGES BETWE-

EN THE PLATE AND THE DIFFERENTIAL

CASE TO AVOID IRREVERSIBLE DAMAGE

IN THESE PARTS. (FIGURE 11).

NOTE:

If necessary, turn the sun gear to make it easier to remove.

• Loosen the nut and the Ring Gear screw (Figure 112).


Figure 9

Figure 11

11

Disassembly

Figure 14

Figure 12

Measure and record the clearance value of the teeth of the hipoidal gear pair. Refer to Setting the backlash gear section (Figure 13).

WARNING:

Before measuring, remove the entire oil in the ring gear and pinion with one of the recommended solvents in the Cleaning section and then, dry according to Drying section instructions.

Figure 15

C. Manually remove the bearing caps and the adjusting rings. (Figure 16)

Important: If necessary, stroke slightly the caps with a plastic hammer in obliquely, to loosen them

• Remove the Bearing Cage (Figure 17).

12

Figure 13

Bearing Caps Removing

A. Remove and discard the cotter pin of right side adjusting ring (Figure 14);

B. Loosen the bearing cap screws (Figure 15);

Figure 16


Disassembly

C. Remove the satellite case and the thrust washer, using a suitable support (Figure

20);

Figure 17

Bearing Cage Disassembly

A. Loosen the screws that hold the ring gear and the two halves of the bearing cage. (Figure 18);

B. Separate bearing cage half flange of the gear, using a suitable puller (Figure 19);

Figure 20

D. Separate the ring gear from the bearing cage – Simple Half, if it is necessary to replace one of these parts;

NOTE:

To remove the case, use preferably a press or tap with a hammer in a brass pin, supported in the inner face of the case.

E. If necessary, remove the bearing cones from the case halves, using an appropriate puller or a press (Figures 21 and 22)

Figure 18


Figure 19

Figure 21

13

Disassembly

C. Separate the two halves of the satellite case and remove its internal components in the sequence specified by the Figures 25, 26,

27 and 28;

Figure 25

Figure 22

Satellite Case Disassembling

A. Mark the two halves of the case and the spider with a not washable ink, in order to make sure the reassembly in its original positions. (Figure 23).

Figure 26

Figure 23

B. Immobilize the satellite case in a suitable device and release the fixing screws of the two halves (Figure 24).

D. Remove the satellite case – planetary half from the device;

E. Mark the axes of the planetary gears and the case before disassembling, so that the original position of these parts can be kept during the reassembly;

14

Figure 24

Figure 27


Disassembly

Figure 28

Figure 30

F. Bata os pinos de travamento para dentro dos eixos das engrenagens planetárias (Figure 29).

The length of the locking pin is smaller than the diameter of the shaft gears, so that the removal of the shaft can be easily done after the pin is within the axis.

NOTE:

We caution that the locking pin is installed in a BLIND HOLE. Therefore, the operation of hitting the pin into the shaft must be made with light hammer strokes, just enough to allow the free passage of the shaft (Figure

30);

CAUTION:

DO NOT APPLY STRONG HAMMER TAPIN-

GS BECAUSE, AS THE HOLE IS BLIND, THE

END OF THE PIN MAY MARK THE EYE OF

THE SATELLITE CASE – PLANETARY HALF.

G. Remove the axes, planetary gears and inner and outer washers (Figure 31).

CAUTION:

DURING PLANETARY GEAR REMOVAL,

BE CAREFUL TO NOT LOSE OR MIX THE

ROLLERS AND SPACERS OF A GEAR WITH

THE OTHER. PUT THE GEAR ROLLERS IN

PLASTIC BAGS.

Figure 29

• Immobilize the fork/flange of the universal joint with a suitable tool and release the pinion nut (Figure 32).


Disassembly

PLANETARY

GEAR

AXLE

OUTER

WASHER

ROLLER

Important:

Do not remove this component with hammer strokes. It may cause warping and make deep marks on the bearings, preventing a possible reuse of them (Figure 34).

SPACER

INNER

WASHER

Figure 31

Important:

To remove the seal easily and safely, insert a screw driver between the flange and the seal case, making lever movements at various points so that the seal is expelled gradually, with no damages to the pinion case.

16

Figure 32

• Remove the fork/flange from the universal joint using a suitable puller. (Figure 33).

Figure 34

• To remove the case, release its fixing screws and washers (Figure 35).

Figure 33

Figure 35


Disassembly

CAUTION:

DO NOT INSERT WEDGE OR CHISEL BE-

TWEEN PINION CASE AND DIFFERENTIAL

CASE TO AVOID IRREVERSIBLE DAMAGE

IN THESE PARTS, AS WELL AS THE AD-

JUSTMENT SHIMS.

Important:

Do not hammer the pinion to remove it. Damage to the bearings and impossibility of reuse may result.

Remove and tie the adjustment shims of pinion case, so that its original position can be kept during the assembly in case of reuse of them

(Figure 36).

B. Remove manually the front bearing cone;

C. Remove, if necessary, the front and rear bearing cups by using a suitable puller or a press

(Figure 38);

D. Remove the adjusting shims manually from the pinion shaft;

E. If necessary, remove the rear bearing cone by using a suitable puller or a press (Figure

39);

F. Remove and discard the snap ring using appropriate pliers;

Figure 36

Pinion Case Disassembly

A. Pull the pinion using a suitable puller or a press (Figure 37);

Figure 38


Figure 37

Figure 39

17

Cleaning – Drying – Inspection – Storage

G. If it is necessary, remove the spigot bearing using a suitable puller or a press (Figure

40);

Carefully remove all gasket particles.

Refer to CHEMICAL GASKET.

Clean inside the case to remove any impurities loosened during the removal of the differential, using the previously mentioned solvents.

Carefully clean the breather plug (air jet can be used). If the breather is blocked or damaged, replace it.

Figure 40

Cleaning

The unit may be externally washed, in order to make easier its removal and disassembly.

In this case, all the gaps must be plugged to avoid water or humidity inside the unit.

CAUTION:

BLOCKED BREATHER PLUGS CAUSE THE

INCREASING OF THE INTERNAL PRESSU-

RE OF THE UNIT. OIL LEAKAGE THROUGH

THE SEALS MAY RESULT.

Drying

Parts must be dried immediately after cleaning.

Dry the parts using soft and clean cotton rags.

Important:

We do not recommend washing the unit after it is removed from the case. When this cleaning system is used, water is retained in the components. This can lead to oxidation (rust) on critical parts and enable the movement of these particles of soot in the oil. The premature wear of bearings, gears and other parts can be caused by this practice.

NOTE:

Except for bearings, parts can be dried with compressed air.

Inspection

It is very important to inspect all components of the unit totally and carefully before reassembling. This inspection will show parts with excessive wear or cracks, which should be replaced.

Thus, the unit should be completely disassembled, because it is not possible to clean it up properly otherwise.

Wash all components with machined or rectified surfaces (gears, bearings, shims, cross) using appropriate petroleum-based solvents such as diesel or kerosene.

The correct replacement will prevent future failures with high costs. MERITOR prefers not to reuse parts, because the cost may be much higher in the future, making it not worth the savings achieved at the time of the repair.

DO NOT USE GASOLINE

Wash cast parts (satellite case, bearing cups, differential case inside) using the previously mentioned solvents.



Bearings Inspection

Inspect all cylindrical rollers / tapered rollers bearings (cups and cones), including those that were not removed from its mounting seats and replace them in case if you find any of the following mentioned defects:

C. Wear (with visible depression) on the cup track or cone and / or deep indentations, cracks or breaks in the cup seat and / or cone, or on the surfaces of tapered rollers

(Figure 43);

Remove the bearings to be replaced with suitable devices (puller or press).

D. Corrosion (caused by chemical action) or cavity on the operating surfaces (Figure

44);

Avoid the use of punches and hammers that can damage also the seats where the bearings are mounted.

A. Severe wear on the wide face of tapered rollers, with almost total elimination of the central undercut, and / or radius worn with sharp edge in the wide face of rollers (Figure 41);

Figure 41

B. Friction signs in the cage of the tapered rollers (Figure 42);

Figure 43

E. Flaking or peeling of the cup surface and / or cone (Figure 45).

Figure 44


Figure 42

19


20

Figure 45

Hypoid Generoid Pair Inspection

Inspect these gears for wear or damage like: cracks, depressions, scores and chips. Check the seats of the bearing cones and the splines of the pinion as well.

NOTE:

The generoid hypoid drive pinions and ring gears are machined in matched sets to ensure the ideal position of tooth contact.

Thus, when it is necessary to replace a damaged ring gear or pinion, both drive gear and pinion must be replaced as a set.

Satellite Case Set Inspection

Check the components of the differential system and replace the parts that present depressions, cracks, excessive out-of-roundness of bores and half rounds or major wear in the work surfaces. Also inspect the work areas specified below:

Planetary System Inspection

A. Inspect the diameters and the teeth of the side and sun gears and the straight teeth of hypoid ring gear for wear and damage.

Those parts that have cracks, depressions, scoring or chipping must be replaced;

B. Inspect all contact surfaces of the planetary gear thrust washers. If any of them show excessive wear, depressions or warping, replace them all;

C. Inspect all bearing rollers and spacers

D. Inspect the mounting seats of the planetary gears in the satellite case – planetary half.

Check that the bores are free of burrs at both ends;

E. Inspect the diameters of the planetary gears axes. If any of the axes shows wear, grooves, or depressions in the diameter, replace all of them;

F. Inspect the speed changing fork and the low speed engaging teeth (locking plate) and replace parts with wear, warping or depressions.

A. Thrust washer seats, half rounds for installing the legs of the spiders on both halves of the satellite case;

B. Contact surfaces for thrust washers of satellites and planetary;

C. Spider legs;

D. Teeth and splines of the side gears;

E. Teeth and bore of all satellites.

Semi-Axes Inspection

Check for notches and excessive wear of the splines and for out-of-roundness of the flange bores.

Differential Case Inspection

Check for cracks on any surface or burrs on the machined parts.

Important:

If it is necessary to replace a pinion or side gear, the whole set should be replaced, including the thrust washers. A combination of new and used parts could cause premature failure of the set.


Maintenance / Restoration

Universal Joint Fork / Flange Inspection

Replace fork / flange of the universal joint in case it presents excessive wear in the Oil Seal

Lips work area.

Case Inspection

Check for crack signs; loosen fasteners, burrs or grooves on the machined surfaces.

E. Remove grooves, marks, burrs or other imperfections of the machined surfaces;

F. Threads must be clean and without damage to get an exact fit and proper tightening torque;

G. Whenever possible, use a press to the reassemble of the parts;

H. Tighten all fasteners and locking components with the values specified on the section TIGHTENING TORQUE;

I. Remove any burrs or grooves from the case.

Estocagem

After the parts have been cleaned, dried and inspected, they must be assembled immediately or covered with a thin film of oil as specified in Section LUBRICATION for the purpose of preventing oxidation.

The parts that have to be stored must be covered with a reasonable coating of oil or any antioxidant and kept in closed boxes or wrapped for protection from dust, humidity or rust

(except for components already protected by paint, galvanization, etc.).

Restoration

In the interest of safety and preservation of the life of the maintenance being performed, MERI-

TOR recommends that repairs not be made by welding operation, which can affect the structural integrity of components, and distort those already undergoing heat treatment processes.

The weld repair can only be approved where strict controls are imposed with equipment normally only found in manufacturing locations.

Maintenance

Replace all the parts that show wear or are damaged and always use Meritor Genuine Parts, to ensure a maintenance service with satisfactory results, once the use of non-genuine parts will diminish the life of the unit.

Important:

In deciding whether a part should be repaired or destroyed, have in mind that we, manufacturers, never hesitate to destroy a piece that is somehow doubtful.

For a better instruction, we inform some basic inspection criteria, for the purpose of repairs and/or replacement of components:

MERITOR has adopted liquid adhesive as its main locking element, then, this section describes the needed cautions for a proper use of this liquid adhesive.

A. Replace nuts and bolts that present rounded corners in the head and / or damaged threads;

B. Replace lock washers, flat washers, snap rings and cotter pins;

C. Whenever the unit is reconditioned, also replace the pinion seal, and the fork hinge pin caps;

D. Remove all gasket particles. Refer to CHE-

MICAL GASKET section;

Liquid adhesives set in absence of air and, being liquids, fill quickly and evenly throughout the space between the threads, making possible to obtain a more efficient and safer locking than the existing conventional systems.


Liquid Adhesive

PRODUCT

LOCTITE

THREE BOND

FEATURES OF LIqUID ADHESIVES

TYPE COLOR

271

241

221

RED

BLUE

VIOLET

1334

1305

1341

RED

GREEN

BLUE

SETTING TIME

2 HOURS

6 HOURS

6 HOURS

6 HOURS

6 HOURS

10 HOURS

Disassembling

Use approved mechanical disassembling procedures to take apart the components that were originally assembled with liquid adhesive.

In this case, apply the minimum torque value recommended by MERITOR. If the screw or fastener does not turn, its condition is satisfactory. If the fastener turns, remove it and apply the procedures described in this section.

WARNING:

Do not use any impact wrench nor hammer the fasteners in order to avoid damages to its heads.

If the removal of a nut, for instance, is difficult due to the wear of its head or because of the required torque, reduce the resistance of the liquid adhesive by heating the head of this component to approximately 150ºC (320°F), while trying to loosen it. This procedure must be done slowly to avoid thermal tensions in the components of this set.

Cleaning

Carefully clean the threaded holes and the threads of screws, nuts and studs to eliminate dirt, oil, grease or humidity. This removal must be done with a cleaning agent such as trichloroethylene or other chlorinated solvent.

Applying Procedures

A. Apply the liquid adhesive so that it covers all the spaces between the threads. In case of internal threads (with blind holes), apply

4 to 6 drops into the threaded hole. (Figure

46).

NOTE:

When the hole is a CLOSED HOLE, apply the liquid adhesive to its thread, because when the liquid adhesive is applied to the thread of the screw and it is introduced, the air inside the hole is pushing against, expelling the liquid adhesive.

B. Tighten the fixing components to the torque values specified in the section TIGHTE-

NING TORQUES.

Reassembling

Before starting this operation, check the applying locations as specified in the section Reassembly. In the case if there are fasteners which had adhesive applied originally but were not removed during the disassembly, check the torque condition of each one of them.

22

Figure 46


Liquid Adhesive

Description

Chemical gasket material is a substance with a pasty consistency that sets at ambient temperature forming a resistant packing. The gasket materials adopted by Meritor are:

174 and 574 (LOCTITE) and NEUTRAL SILI-

CON (DOW CORNING 780, or 5699 LOCTITE

TREE BOND 1216).

CAUTION:

THE EXCESSIVE APPLICATION CAU-

SES THE DISPLACEMENT OF CHEMICAL

GASKET INTO THE UNIT AND DIFFICUL-

TIES IN FUTURE DISASSEMBLIES. FAILU-

RES IN THE APPLICATION OF THE GASKET

CORD COULD BE THE CAUSE OF FUTURE

LEAKAGE.

Cleaning

Carefully clean both joining surfaces to eliminate particles of the previous gasket, oil, grease or humidity. The removal of these particles must be done with a flat-bladed tool or sand paper, followed by cleaning with an oil-free solvent, like xylol, toluol or methyl ethyl ketone.

Avoid making scratches in these surfaces because this could cause leakage in the future.

B. After applying the chemical gasket, joint immediately both mating surfaces in order to spread the gasket cord properly;

C. Tighten the fasteners to the required torque value specified in the Section TIGHTENING

TORQUES.

Pinion Case Assembling

A. Assemble the new bearing cups (rear and front), using suitable tools or a press. (Figure 48);

Drying

Be sure that the surfaces to be joined are perfectly dry before applying the chemical gasket.

Applying Procedures

A. Apply a continuous gasket cord of approximately 3 mm in diameter when the joint is neutral silicone or apply with a brush when it is 174 and 574 (Loctite), all the way around of one of the mating surfaces and all the mounting holes to ensure a complete seal that prevents leakage (Figure 47).

WARNING:

1. Check that the cup seats are clean and free of burrs.

2. During the assembling operation, be sure that there is no material pullout in the pinion case.

3. Check that the cups are perfectly seated on its housings.

B. Install the new bearing cone using a suitable tools or a press (Figure 49);

WARNING:

Check that the cone is perfectly seated on the pinion.

3MM DIAMETER


Figure 47 Figure 48

23

Reassembly

24

Figure 51

C. Install the new spigot bearing using a suitable tool or a press (Figure 50);

Figure 49

WARNING:

Make sure that the bearing is correctly seated on the pinion. For installation use an adequate driver that pushes only on the inner race of the bearing.

A. Rest an appropriate driver bush on the press table and position the new spigot bearing on the driver (Figure 52);

B. Rest an appropriate driver bush on the press table and position the new spigot bearing on the driver (Figure 53);

The spigot bearing for the Differentials 230 and

240 may present an optional building form (Figure 51);

Check the type to be installed before installing this component. The optional construction may require a specific assembling process.

Figure 52

INNER RACE

RING

DRIVER BUSH

Figure 53

Figure 50


Reassembly

C. Place the pinion on the spigot bearing;

D. Press the pinion until it seats firmly against the spigot bearing;

E. Release the pressure and lower the drive pinion and spigot bearing assembly;

J. Press the front bearing cone and check the preload. Refer to PINION BEARING PRE-

LOAD ADJUSTMENT section (Figure 56).

K. Install the new pinion seal using a suitable tool (Figure 57);

WARNING:

After assembling, the thrust ring must be positioned towards the pinion or the rollers and the outer race may be loosened. Otherwise, in case of installation of spigot bearing by thrust ring process specification, the pinion may be damaged.

WARNING:

For 230 Axes, be sure that the seat is free of oil or grease before installing the seal.

F. Install a new snap ring with a suitable snap ring plier (Figure 55);

G. Lubricate bearing cups and cones with the oil recommended in the section LUBRICA-

TION;

H. Install the bearing shim in the hypoid pinion shaft;

I. Place the hypoid pinion in the cage;

Figure 56

PRESS

Figure 54

Figure 57


Figure 55

25

Reassembly

L. Apply Lithium Soap Based Grease for extreme pressure to the Seal Lips (Figure 58);

L1. For 230 Axes, apply sealing paste (3M Industrial Adhesive 847) on the external surface of the seal (Figure 58);

Reassembly

L. Before installing the new seal, be sure that the Pinion case and the seal seating surfaces are free of any dirt.

Figure 59

26

TRIPLE LIPS FOR ALL AXES

Figure 58

M. Place the fork/flange of universal joint in the pinion slot;

Figure 60

NOTE:

In case if it is necessary to replace the dust deflector, use a suitable tool.

N. Install the pinion nut and tighten it manually.

C. Install the washer and fixing screws of the pinion case and tighten them with the torque specified in the Tightening Torques section (Figure 61);

D. Immobilize the universal joint fork/flange with a suitable tool and tighten the pinion nut with the specified torque of the Tightening Torques section (Figure 62);

Pinion Case Installation

A. Select and install the adjustment shims for the pinion case using guiding pins (Refer to

Pinion Installation section) and apply liquid gasket Loctite 174 or 574 in the differential case before installing the shims (Figure 59);

B. Install the pinion case (Figure 60);

Figure 61


Reassembly

B. Place the planetary gears (with rollers and spacers) and the washers (inner and outer) in the satellite case (planetary half) aligning the holes of the washers and case to make easier the installation of the axes (Figure

64);

C. Install the axes of planetary gears;

Figure 62

E. Install a torque wrench on the pinion nut and check the resistive torque value to rotate the Generoid hypoid pinion. Increase, as necessary, the torque applied on the pinion nut (up to the maximum torque allowed), to meet the values specified on the PINION

BEARINGS section.

WARNING:

Before reinstalling the planetary gear shaft, inspect the eye of the case and make sure that there are not burrs which could damage the diameter of the axle. Be sure that the original assembling position of these components was kept. Install the shafts gradually, to avoid damages in the contact areas of the rollers.

D. Install the locking pins (Figure 65);

Satellite Case Assembling

LUBRICATE all the satellite case components before installing them (Figure 63).

A. Apply grease (SHELL 71032 ALVANIA

EP-2 or TEXACO - 995 MULTIFAK EP-2) in the holes of the planetary gears. Install the rollers and the spacer in each gear (Figure 63).

Figure 64


Figure 63

Figure 65

27

Reassembly

E. Immobilize the satellite case planetary-half using a suitable device (Figure 66);

F. Place the planetary – short hub with its thrust gear, in the case planetary-half (Figure 67);

28

Figure 68

Figure 66

WARNING:

We caution that the inadvertently installation of the planetary in the case planetary-half, may result in the inversion of its original positions

(Figure 69).

PLANETARY HALF CASE

SIMPLE HALF

CASE

THRUST

WASHER

Figure 67

G. Place the satellites, its thrust washers and the spider (Figure 68);

H. Then, place the planetary – long hub, and its thrust washer;

I. Install the case satellite-half, observing the original alignment;

PLANETARY LONG HUB

PLANETARY SHORT HUB

Figure 69


Reassembly

J. Install four fasteners in the main differential case equidistant to each other. Tighten them to the torque value specified in Tightening Torques Section;

K. Remove the satellite-set case from the device;

L. Check the rotation resistance of the planetary satellite-set. Refer to Satellite system /

Planetary section;

M. Apply Liquid Adhesive (Loctite 271 or

THREE BOND 1305), to the fixing screws of the satellite case. Refer to the section Liquid Adhesive;

N. After check / correct, install and tighten the remaining fixing screws of the satellite cases to the specification of Tightening Torques section, install the satellite case thrust washer with grease, to avoid it falling into the differential case during the installation.

Differential Case Assembling

A. Install the new bearing cones in both halves of the differential case using a suitable tool or a press (Figure 70 e 71);

Figure 71

C. Install the satellite case and its thrust washer using a suitable device (Figure 20);

D. Install the case half-flange in the ring gear

(Figure 72);

E. Apply Liquid Adhesive (Loctite 271 or

THREE BOND 1305), to the threads of the ring gear fixing screws. Refer to Liquid

Adhesive Section;

F. Install and tighten the fixing screws according to the Tightening Torques section specification (Figure 73).

WARNING:

1. Make sure the cone seats are clean and free of burrs.

2. During the assembling operation, be sure that there is no material pulling off from the Differential Case.

3. Make sure that the cones are perfectly seated in its housings.

B. Install the Differential Case simple half in the ring gear;

Figure 72


Figure 70 Figure 73

29

Reassembly

Installation of Differential Case Set

A. Temporarily install the bearing cups, adjusting rings, bearing caps and its Capscrews.

Tighten the Capscrews to the torque value specified in Tightening Torques section;

B. Seat the cap in the cones and install the set on the differential case (Figure 74);

C. Place the adjusting rings on the caps and manually turn them, up to get them seated on the bearings (Figure 75);

WARNING:

During Differential Case installation, there is a tendency of the set sliding towards the left bearing cap, making harder the assembling operation. Thus, it is recommendable to assemble first the Left Side Bearing Cap adjusting ring

(ring gear side).

D. Place the bearing caps and tighten them slightly. Try to turn the rings (Figure 76);

WARNING:

If it is not possible to turn the rings manually

(with no forcing), they must be out of position.

Remove the bearing caps and reposition the adjusting rings, to avoid irreparable damage to the differential case and bearing caps.

Figure 74

30

Figure 76

Figure 75

E. Apply Liquid Adhesive (Loctite 271 or

THREE BOND 1305), to the threads of the

Capscrews. Refer to the Liquid Adhesive section;

WARNING:

The liquid adhesive must be applied only after bearing preload, gear backlash and ring gear and pinion teeth contact adjustments have been performedo.

F. Install and tighten washers and Capscrews to the specified torque values of the section

Tightening Torques.


Reassembly

• Adjust the differential bearings preload. Refer to the section Bearing Cage Bearings.

• Adjust the Backlash Gear. Refer to the section Backlash Gear.

• Check the tooth contact of the hypoid pair.

Refer to the section Tooth Contact, Ring

Gear and Pinion

• Apply Liquid Adhesive (174 and 574 LOCTI-

TE) to the Ring Gear Thrust Screw.

• Install and adjust the ring gear thrust screw.

Refer to the section Adjusting The Ring Gear

Thrust Screw.

Assembling the Speed Change System

A. Install the clutch plate through the following procedure:

Figure 77

Model: 220

a) Place the clutch plate; b) Apply Liquid Adhesive (Loctite 241 or

THREE BOND 1334), to the threads of the

Clutch Plate fixing screws.

c) Install and tighten the new fixing screws of the plate to the specified torque values of the section Tightening Torques.

Modelo:230/240

a) Screw the four fasteners of the Locking Plate as much as enough to keep a dimension of 26,6-27,2mm, between the top of the fastener and the contact surface of the plate

(on the differential case); b) Place the locking plate upon the fasteners; c) Install new conical washers; d) Apply Liquid Adhesive (Loctite 241 or

THREE BOND 1334), to the threads of the fasteners; e) Install and tighten the fixing nuts to the specified torque values in the section Tightening Torques (Figure 77).

PLUGS

Figure 78

D Apply sealing paste 3M – Industrial Adhesive 847 to the outer surface of the plugs;

E Install new plugs and the shift shaft. (Figure

79).

B. Install the new locking screw which holds the adjusting ring at the Ring Gear side and the cotter pin which locks the ring in the opposite side;

C. Place the sun gear and the fork (Figure 78);

Figure 79


Reassembly

F. Apply a silicon adhesive cord to the contact surface of the mechanism in the case and then, install the Shift Mechanism (Figures

79 A and 79 B) (Figures 79 A and 79 B)

32

Figure 79A

Figure 80

D. Gradually press the center of the diaphragm up to reach the base of the mechanism

Figure 79B

CAUTION:

1 - THE DIAPHRAGM SHOULD BE ALIG-

NED SO THAT THE HOLES MATCH THE

FASTENERS.

2 - DO NOT FORCE THE DIAPHRAGM

BASE. THE METALLIC REINFORCE-

MENT SHOULD BE DAMAGED.

3 - THE CENTER OF THE DIAPHRAGM

SHOULD STAY NEARLY 2.7 MM ABOVE

THE FLANGE SURFACE, SO IT IS NOT

TENSIONED.

Installation of the Mechanism Diaphragm (When Existing)

A. Clean and Inspect the Fork Shaft for scratches and burrs;

B. Apply extreme pressure Lithium Soap based grease, to the fork shaft;

C. Place the diaphragm and the retention spring on the fork shaft (Figure 80);

Important:

Before positioning this component, be sure that the following points are correct: assembling side with alignment of the holes with the fixing base fasteners. This is important because the diaphragm has only one mounting position.

E. Make sure the diaphragm is assembled without torsion;

F. Wipe excess grease from the fork shaft.

Installation of Differential

A. Check the case for differential fastening studs looseness (if applicable). Apply Liquid

Adhesive (Loctite 271 or THREE BOND

1305) to the loosen fasteners;

B. Reinstall and tighten these fasteners as much as enough to the total engagement of the threads;

C. Apply NEUTRAL SILICON to the mouth of the case. Refer to the section Chemical

Gasket;


Reassembly

D. Before starting the installation, make sure that the mechanism is set to Low Speed

(LS), to avoid interference between the sun gear and the mouth of the case and allow an easy installation of the differential;

E. Place the differential on the case;

F. Start the installation of the differential in the case with four flat washers and four nuts, equidistantly spaced.

• Install the semi-axes.

• Install and tighten the drain plug to the specified torque in the section Tightening Torques.

WARNING:

After tightened, at least one of the threads should remain above the mounting surface.

CAUTION:

DO NOT TRY TO INSTALL THE DIFFEREN-

TIAL ON THE CASE USING A HAMMER.

THIS PRACTICE MAY DAMAGE THE FLAN-

GE AND CAUSE OIL LEAKAGE.

• Fill the unit with the oil specified in the section

Lubrication

• Install and tighten the oil filling and level inspection plug to the torque specified in the section Tightening Torques

Important:

1. Install the flat and tapered (if any) washers on all of the studs located in places that are not easily accessible. In some instances, it is impossible to install them after the differential is in its final position in the case.

2. Tighten the four nuts with flat washers in an alternated sequence, to drive the set aligned to the next nuts or screws.

3. In case if there are screws fixing the differential apply Liquid Adhesive (Loctite 241 or

THREE BOND 1334) to them. Refer to the

Liquid Adhesive section.

WARNING:

After tightening, at least one of the threads should remain above the mounting surface.

Ring Gear Thrust Screw Adjusting

A. After the assembly settings, screw the bolt with its nut until its end touch the rear face of the ring gear and then return 1/3 turn back to ensure a clearance of 0.6 to 0.9 mm

(Figure 81). Tighten the nut to the specified torque in the section Tightening Torques.

• Install the shift mechanism in the differential with application of chemical gasket (NEU-

TRAL SILICON).

WARNING:

Be sure that the shift fork position is compatible with the rest position of the shift mechanism drive shaft.

CLEARANCE:

• Install and tighten the fixing washers and nuts of the mechanism to the specified torque in the section Tightening Torques.

• Connect the shaft drive to the mechanism line.

Figure 81


Pinion Bearings

The preload control avoid the bearings to operate with excessive pressure (reducing wear life) or with free play (produces noise and reduces wear life of the differential

The preload is obtained through the installation of a selection shim between the pinion bearing cones (Figure 82).

PINION BEA-

RINGS ADJUS-

TING SHIM

34

Figure 82

Identification of Pinion Bearing Adjusting Shims

It is available for setting a series of shims that vary in thickness, as indicated in the tables “A” and

“B”.

IMPORTANT:

The thickness value is marked in each pad.

New Bearings

N.m

1,7 - 4,0 lbf.in

15 - 35

WARNING:

These values must be obtained before installing the seal in the pinion case.

CODE

028070

028071

028072

028073

028074

028075

028076

028077

028078

028079

028080

028081

028082

THICKNESS

(MM)

11,89

11,91

11,94

11,96

11,99

12,01

12,04

12,07

12,09

12,12

12,14

12,17

12,19

CODE

028083

028084

028085

028086

028087

028088

028089

028090

028091

028092

028093

028094

028095

N.m

USED Bearings lbf.in

1,1 - 2,3 10 - 20

THICKNESS

(MM)

12,22

12,24

12,27

12,30

12,32

12,34

12,37

12,40

12,42

12,45

12,47

12,50

12,52

CODE

028096

028097

028098

028099

028100

028101

028102

028103

028104

028105

028106

028107

THICKNESS

(MM)

12,55

12,57

12,60

12,62

12,65

12,67

12,70

12,73

12,75

12,78

12,80

12,83

Table “A” for models 220/230


Pinion Bearings

CODE

029034

029035

029036

029037

029038

029039

029040

029041

029042

029043

029044

029045

029046

THICKNESS

(MM)

18,30

18,33

18,35

18,38

18,40

18,43

18,45

18,48

18,51

18,53

18,56

18,59

18,61

CODE

029047

029048

029049

029050

029051

029052

029053

029054

029055

029056

029057

029058

THICKNESS

(MM)

18,64

18,66

18,69

18,72

18,74

18,77

18,79

18,82

18,85

18,87

18,90

18,92

CODE

029059

029060

029061

029062

029063

029064

029065

029066

029067

029068

029069

029180

THICKNESS

(MM)

18,95

18,98

19,00

19,03

19,05

19,08

19,11

19,13

19,16

19,18

19,21

19,24

Table “B” for model 240

We recommend that the initial assembling is done with the shims of the recommended range in the table “C”, which allow to obtain immediately (in most cases) the desired setting:

WARNING:

The identification is marked in the outer diameter or in one of faces of the shim.

MODEL

220/230

240

RECOMMENDED RANGE

MM INCHES

12,30 - 12,50 0,484 - 0,492

18,79 - 18,90 0,740 - 0,744

Tabla “C”

Drag Torque Determining Procedure

(Using a press)

A. Lubricate all pinion bearings with the oil recommended in the section Lubrication;

B. Press the front bearing cone and turn the pinion cage several times to ensure a suitable seating between caps and cones. Keep the pinion cage under pressure load, according to specification of table “D”;

MODEL

220

230

240

LOAD (TON)

11

11

14

Tabla “D”


Pinion Bearings

C. Wrap a cord around the pilot diameter of the pinion cage with a dynamometer (good quality balance), tied at its end;

D. Pull the dynamometer horizontally and note the value (pounds or kilograms) recorded in its scale;

NOTE:

For convenience, we reported in the table “E” the readings that should be obtained to meet the preload values.

NEW BEARING USED BEARING

MODEL

KG LB KG LB

240 2,1 - 4,8 4,5 - 10,6 1,3 - 2,8 3,0 - 6,0

220/230 2,6 - 6,2 5,8 - 13,5 1,7 - 3,6 3,8 - 7,7

Table “E”

E. Note the value obtained with the rotating set, but not the starting value (Figure 83);

PRESS

36

Figure 83

F. Measure the pilot diameter of the pinion cage and then divide by two to determine the value of the radius;

NOTE:

For convenience, we inform on table “F”, the radius value to be considered.

MODEL

240

220/230

RADIUS

CM

8,4

6,6

IN.

3,31

2,60

Table “F”


Pinion Bearings

G. Multiply the value of “E” item by the “F” item and then make the following calculation: kg x cm = result in kgf. Cm

lb x inches = result in lbf.pol

Drag Torque Determining Procedure

(Without press)

If a press is not available during the service operation, use the following procedure:

H. Check if the obtained result matches the specified limits.

If the value found is over the maximum specified limit, replace the shims by others of greater thickness.

If the value found is below the maximum specified limit, replace the shims by others of smaler thickness.

Example of Calculation

Data radius - 8,4 cm (3,31”) reading in the dynamometer 2,3 kg (5,0 lb).

Calculation Procedure

2,3kg x 8,4 cm = 19,3 kgf.cm

5,0lb x 3,31” = 16,55 lbf.pol

Converting to N.m

19,3 x 0,098 = 1,9 N.m

16,55 x 0,113 = 1,9 N.m

A. Lubricate all the pinion bearings with the oil specified on the section Lubrication;

B. Install the fork/flange of the universal joint

(without the pinion seal);

C. Immobilize the pinion (by the fork/flange of universal joint), using a suitable device;

D. Tighten the pinion nut to the minimum value specified in the section Tightening Torques;

E. Turn the pinion cage several times to ensure a suitable seating between caps and cones;

F. Do then the same procedure specified on pages 53 e 54 (from “C” to “G”);

G. If the value is found below the minimum specified limit, gradually tighten the pinion nut (if necessary, up to the maximum torque value specified in the section (Tightening

Torques) to obtain the desired preload;

WARNING:

Note the value obtained with the rotating set, but not the starting value.

WARNING:

To convert lbf.pol in N.m multiply it by the factor of 0,113 and kgf.cm in N.m multiply it by a factor of 0,098.

H. If, after tightening to the maximum torque the desired preload is not obtained, replace the shims by others of a smaller thickness and repeat the inspection procedure;

I. Remove the fork/flange of the universal joint and continue the reassembling of the differential.


Pinion assembly

This adjustment helps to position the drive pinion in relation to the ring gear for the purpose of ensuring the ideal position of tooth contact between ring gear and pinion.

The desired distance is obtained by the installation of a shim set under the drive pinion bearing cage (Figure 86).

ADJUSTING

SHIM SET

OF THE

DRIVE

PINION

BEARING

CAGE

Figure 86

Identifying the Drive Pinion Bearing Cage Adjusting Shims

It is available a series of adjusting shims for this adjustment. They are differentiated by its thickness (see table “G”).

MODEL

240

220

230

CODE

028455-6

028454-8

028453-0

027288-4

027289-2

027290-6

THICKNESS (MM)

0,25

0,13

0,08

0,13

0,25

0,08

Table “G”

NOTE:

Shims are not identified because their difference in thickness is quite noticeable.

The proper combination of these parts will form the shims packet, which should ensure the desired position of the pinion.

Important:

The package should always be made of a minimum of three pieces, and the thicker shim should be placed at its end so as to ensure maximum sealing.


Shims Determination Procedure

(With caliper)

Pinion assembly


(Without caliper)

A. Write down the nominal mounting dimension (ND) for the drive pinion. This dimension is the nominal distance taken from the center of the ring gear to the rear drive pinion bearing cone seating face (Figure 87);

This process consists of a mathematical calculation, and the result is sufficiently satisfactory when only the ring gear and drive pinion set is replaced.

Other components that can affect the proper position of the drive pinion are: the differential case, the drive pinion bearing cage and the inner pinion bearing. Therefore, if any of these components need to be replaced; this mathematical process may be used as a first attempt to select the shims for the proper adjustment in the contact of the drive pair.

Figure 87

ND

219,08

206,38

200,00

Table “H”

A. Take note of the variation value (PV) on the drive pinion to be replaced;

B. Observe the variation value (PV) on the new drive pinion. If the value is the same as the original drive pinion, the thickness of the original shim pack must be maintained.

A table “H” mostra o valor da DN a ser considerado para cada modelo:

MODEL

240

230

220

If the value is different, perform the following calculations:

B1. Measure and write down the thickness of the original shim pack (pack thickness PT);

B2. Check the variation value (PV) stamped on the head of the original drive pinion. If this number is (+), subtract this value from the thickness dimension of the original shim pack. If it is (–), add it.

B. Identify and right down the drive pinion variation (PV);

All drive pinions have an individual variation with respect to their ND. This variation, expressed in hundredths of a millimeter, and a + or

– sign is stamped on the pinion’s head (Figure

88);

The resulting value will establish a master thickness for shim packs used for the assembly of a drive pinion whose ND dimension is equal to zero.

B3. Take note of the value obtained in Step B2 to use it in the calculation of the thickness for the shim pack of the new drive pinion.

B4. Observe the variation value (PV) of the new drive pinion. If the value is (+), add it to the value obtained in Step B3. If it is (–), subtract it;

B5. The final result obtained will establish the thickness of the new shim pack to be used in the installation of the new hipoidal pair.

Figure 88


Pinion assembly

Example of Calculation “1”

Data:

EP (original pack) .........................0,90

VP (original drive pinion..............+0,05

VP (new pinion) ...........................-0,13

Calculations

EP (original pack) .........................0,90

VP (original drive pinion) .............-0,05

EP (master pack) ........................=0,85

VP (new drive pinion) ..................-0,13

EP (new pack) ............................=0,72

Exemplo De Cálculo “2”

Data:

EP (original pack) .........................0,90

VP (original drive pinion) .............-0,05

VP (new drive pinion) ..................-0,13


(With caliper)

WARNING:

In the following operations, ensure the cleaning of the indicated components:

1. Mating surfaces between the components of special tool;

2. Mating surfaces of the components of special tool;

3. Mating surfaces between differential case and drive pinion, which is crucial.

- The special tool is made of the following components: (Figure 90).

1. Centering discs

2. Centering axle shaft

3. Drive pinion simulator

4. Adapters for Drive Pinion Bearing - Rear

5. Locking Washer – Drive Pinion Bearing -

Front

6. Knurled Nut

7. Dial support

8. Shims

40

Figure 90


Pinion assembly

A. According to the model of the rear axle, install the rear bearing adapter in the drive pinion simulator. (Figure 91).

B. Install the rear drive pinion bearing on the adapter. (Figure 92).

Figure 94

Figure 91

E. Install the drive pinion front bearing lock washer and the knurled nut, tightening it manually. (Figure 95).

F. Check if the drive pinion and the differential case contact surfaces are clean and free of scratches or scores.

G. Install the drive pinion cage in the differential case without the adjusting shims. (Figure 96).

Figure 92

C. Install the drive pinion bearing cage on the drive pinion rear bearing with the face to fit the differential facing down (Figure 93).

D. Install the front bearing in the face of the drive pinion cage (Figure 94).

Figure 95


Figure 93

41

Pinion assembly

K. According to the differential model, install specific centering discs with their respective shaft in the bearing housing of the differential case.

L. According to the rear axle model, select the proper shim:

Figure 96

MODEL

220

230

240

SHIM PACK

4.72

11.10

23,80

Then install it over the upper end of the pinion simulator, after making sure that the contact surfaces of both parts are absolutely clean (Figure 99).

H. Install four capscrews and initially tighten them in a cross sequence. (Figure 97).

I. Then with a torque wrench in the same cross sequence, apply the final torque to:

67 - 91 lbf pé ( 90 -125 N.m). (Figure 98).

J. Make sure the differential case assembly bearing housing and the centering discs from the special tool are perfectly clean and lubricate them with a thin oil film.

M. Install a hundredth dial in the bracket. Place the support and the touch probe of the dial over the default shim surface and adjust the instrument at “0” (zero) reading. (Figure

100).

42

Figure 97

Figure 99

Figure 98 Figure 100


Pinion assembly

N. Then, with the dial support firmly positioned on the default shim surface, put the touch probe over the centering shaft.

Continuing, move the probe across the centering shaft up to the pointer of the instrument indicate a maximum value. This value indicates that the probe is exactly over the centering shaft diameter. (Figure 101).

NOMINAL

DIMENSION

Write down the maximum value (MV) indicated by the pointer of the dial indicator.

O. See the value known as nominal dimension of this differential.

Nominal dimension is the distance taken from the seating face of the drive pinion rear bearing to the center of the ring gear. (Figure 102).

Figure 102

P. Check and write down the number stamped on the top of the pinion. This value indicates (according to its preceding signal) how many hundredths of a millimeter have to be added or subtracted from the corrected nominal dimension. (Figure 103).

Each model has a specific nominal dimension, as shown below:

Differential Specific Nominal

Model Dimension

220 200.00

230 206.38

240 219.08

Figure 103

Q. Subtract the maximum value (MV) of the differential nominal dimension from its specific corrected nominal dimension.

The result will be the thickness of the shim pack(s) to be added to obtain proper drive pinion/ring gear tooth contact.

Exemple:

In a 220 differential, we find the following values:

Figure 101

1. Nominal dimension maximum value (MV) of the differential, determined with the help of a special tool:

Vm = 200,70

2. Stamped number in the top of the drive pinion:

-06

3. Specific Nominal Dimension (SND) of this differential model;

Cne = 200,00


Satellite System/Planetary

From these data we get the following:

The number -6 stamped on the top of the drive pinion indicates that its height variation in relation to the differential nominal dimension is 0.06 mm lower than the specific nominal dimension

(SND), so: :

200,00 - 0,06 = 199,94

Therefore, 199.94 is the corrected nominal dimension (CND) for the differential.

To determine the thickness of the shim pack(s) needed to obtain a proper drive pinion/ring gear tooth contact, we subtract CND (corrected nominal dimension) from Mv (maximum value).

Figure 105

B. Put a torque wrench on the end of this device and check the rotation resistance value of the satellite/planetarium assembly. The obtained value must be less than. (Figure

106);

Vm - Cnec = Thickness of the shim pack

200,70 - 199,94 = 0,76 mm

We, therefore, have to add 0.76 mm of shims between the differential and the drive pinion assembly to obtain a proper drive pinion/ring gear tooth contact.

A. Immobilize the differential case and insert the device, which must engage with the splines of one planetary. (Figure 104);

Figure 106

NOTE:

A suitable Inspecting Tool may be built from a cut shaft axle with a welded nut on its end, for attaching the torque wrench (Figure

105);

The preload is obtained through the correct positioning of the bearing adjusting rings (Figure

107).

44

Figure 104

Figure 107


Differential Cage Bearings

Preload Adjusting Method

A. Gradually tighten the “X” ring until the backlash of the ring gear/drive pinion is eliminated (Zero clearance);

Alternative Method

A. Loosen the “Y” ring until axial clearance of the bearings is obtained;

B. Tighten the “X” ring until the backlash of the hypoid set teeth is eliminated (Zero clearance);

WARNING:

Tightening must be gradual so that the ring does not press on the bearing (cup and cone) after the ring gear is seated in the drive pinion.

WARNING:

Tightening must be gradual so that the ring does not press on the bearing (cup and cone) after the ring gear touches the drive pinion.

B. Gradually tighten the “Y” ring until the radial clearance of the bearings is eliminated.

C. Loosen the “X” ring 3 or 4 notches (nut).

D. To obtain the desired preload, tighten the

“Y” ring until the axial clearance is eliminated, and then tighten 2-3 notches more (for new bearings) or 1-2 notches (for used bearings) or tighten it to a torque value of 25-30 lb-ft.

E. Check the Backlash Gear as specified in the section BACKLASH GEAR.

C. Meça a distância entre os pedestais das capas dos mancais (nas diagonais A e B) com um micrômetro adequado (Figure 109) e anote os valores obtidos;

D. Loose the “X” ring 3 to 4 notches or holes and gradually tighten the “Y” ring to expand the bearing caps about 0.006~0.013 inch (0.15~0.33 mm) for new bearings or

0.003~0.006 inch (0.08~0.16 mm) for used bearings, which is the bearing preload;

E. Do a new measurement and compare the result with the values obtained in step “C”.

(Figure 110);

Important:

To move the rings, always use a “T” bar or ordinary bars which engage in two opposite notches (Figure 108). Never hammer the notches with hammers or chisels, as this may cause irreparable damage in the adjusting rings.

Figure 109

Figure 108


Backlash Gear

Figure 110

F. Check if the expansion specified in the step

“D” was obtained. If not, do a new alternated tightening process with measurement/ comparison to obtain the specified expansion.

• Check, then, the runout of the rear surface of the ring gear (Figure 111). If found value exceeds 0.019 inches (0,20 mm), remove the ring gear, check the causes and correct them.

Figure 112

Immobilize the drive pinion, manually rotate the ring gear in both directions and take the reading. The value for the backlash should be between 0.010~0.016 inches (0.25~0.40 mm).

In case if it is necessary to increase or decrease the backlash, loosen the “X” ring and tighten the “Y” ring (or vice versa) in the same proportion, so as not to change the preload of the bearings (Figure 113).

Important:

When the hypoid pair is reused, it is recommendable to keep the original backlash (measure found before disassembling the differential assembly).

46

Figure 111

Important:

The differential case (simple and flange halves) and the locking plate must be inspected and replaced if any engagement problem is found.

INCREASES

THE CLEARANCE

DECREASES

CLEARANCE

Figure 113

Check the backlash gear of the hypoid pair using the following procedure:

Rest the pointer of a dial indicator on one of the ring gear teeth. (Figure 112);

Inspection Process

A. Apply yellow iron oxide (diluted in thin oil) in a number of teeth of the ring gear (Figure

114);

B. Block the ring gear with the help of a lever or a slat and manually rotate the drive pinion, until you have the impression of contact on the convex side (forward gear) of the ring gear’s teeth (Figure 115);


Figure 114

Figure 115

C. Make sure the contact obtained by the manual process meets the standard (Figure

102). If not, use the correction methods listed under “Incorrect Contacts”;

D. Then, remove the yellow iron oxide remaining in the teeth of the hypoid pair.

Satisfactory Contacts

For convenience, we indicate the terminology used in this section in Figure 116.

The contact pattern for the manual process indicates that the position of the gears is correct, resulting in a contact area from the center to the toe and the heel/top and the root of the tooth. This area of contact covers approximately

70~80% of the ring gear tooth’s length (Figure

117).


Teeth Contact, Ring Gear and Pinion

47


CONCAVE SIDE

Incorrect Contacts

Height Variations on the Tooth

If the drive pinion is not at the proper depth, the contact can show tooth height variation. If so, correct its position by varying the thickness of the shim pack under the drive pinion bearing case (refer to Table “J”).

INCREASE

DEPHT CONVEX SIDE

Figure 116

PATTERN FOR MANUAL PROCESS

SHALLOW CONTACT

DECREASE

DEPTH

Figure 119

Figure 117

If the convex side is satisfactory, consider the contact of the concave side of the tooth (reverse gear) automatically accepted.

The pattern with load application shows the resulting contact when the gears approved by manual process suffer the action of a load

(working operation). The contact area extends itself throughout the length of the ring gear tooth (Figure 118).

LOAD APPLICATION PATTERN

DEEP CONTACT

Figure 120

Figure 118



OBTAINED CONTACT

SHALLOW CONTACT

MEANING

This indicates that the pinion is too far from the ring gear, resulting in a contact too close to the top of the tooth (Figure 119).

HOW TO CORRECT

Get the pinion closer by decreasing the thickness of the drive pinion cage adjusting shims pack

(refer to the section Pinion Assembling Distance Adjustment).

This will make the contact moves to the root of the tooth (Figure

117).

DEEP CONTACT

Length Variations on the Tooth

This indicates that the pinion is too close to the ring gear, resulting in a contact too close to the root of the tooth (Figure 120).

Move the pinion away, increasing the thickness of the drive pinion cage adjusting shims pack (refer to the section Pinion Mounting

Distance Adjustment). This will make the contact moves to the top of the tooth. (Figure 117).

Table “J”

Check, then, if the contact has varied in terms of length of the tooth. If so, change the depth of the ring gear varying the gear backlash (see Table “K”).

OBTAINED CONTACT MEANING

CONTACT IN THE EXTREME

END OF THE TOOTH

Indicates that the ring gear is very close to the pinion, causing the contact to be too close to the top of the tooth (Figure 121).

HOW TO CORRECT

CONTACT IN THE HEEL OF

THE TOOTH

Indicates that the crown is too far from the pinion, resulting in a close contact of the heel of the tooth (Figure 122).

Table “K”


Lubrication

CONTACT IN THE EXTREME END OF THE TOOTH CONTACT IN THE HEEL OF THE TOOTH

50

Figure 121 Figure 122

The use of incorrect lubricants or inadequate additives generally is the major cause of differential failure occurrences.

The specified lube oil for differentials must have extreme pressure (EP) features, API-GL-5 service classification of the American Petroleum Institute and meet the requirements of the U.S. military specification MIL-L-2105-C.

This type of oil, better known as hypoid oil, have a lubricating film which is able to bear the load pressure of heavy loads, which makes it adequate for hypoid gears, whose conditions are quite severe.

Viscosity

Generally, the high viscosity degree of monoviscous oil is suitable for high environmental temperatures.

In addition to extending wear time of the gears, the option for multiviscous oil will satisfy the found temperature conditions.

The table below represents the viscosity selection of oils:

MILITARY

SPECIFICATIONS

MIL - L2105 - C/D

MIL - L2105 - C/D

MIL - L2105 - C/D

MIL - L2105 - C/D

MIL - L2105 - C/D

MIL - L2105 - B

MIL - L2105 - B

OIL DESCRIPTION

API GL-5 85W/140

API GL-5 80W/140

API GL-5 80W/90

API GL-5 75W/90

API GL-5 75W/140

API GL-5 90

API GL-5 140

ENVIROMENTAL TEMPERATURE

MÍN.

.

MÁX.

-12 Cº

-15 Cº

-X-

-X-

-26 Cº

-40 Cº

-40 Cº

0 Cº

+4 Cº

-X-

-X-

-X-

-X-

-X-


Lubrication

Inspection and Recommendations

Check, every 1.250 miles (2.000 km), if the oil level is correct.

Perform the draining operation while the oil is still warm. This allows the lubricant to drain freely and more quickly, reducing the time required to completely drain the oil from the differential.

Complete the level or refill until the lubricant drain off slightly by the lower edge of the hole for oil filling and level inspection.

The shaft should not be internally washed with any kind of solvent (kerosene, gasoline, diesel, etc.).

After every oil change, and before applying the vehicle to normal operation, drive within the speed limit of 25 mph (40 km/h), for 5 to 10 minutes or 1 to 2 miles (2 to 3 km) to ensure that all lines have been properly filled with oil. If the differential is a replacement unit not scheduled for immediate use, all bearings and gears should be covered with a good coat of anti-corrosion oil.

In this case, the differential should be kept in a sealed box to be reused, to avoid the contact of dust and other impurities with the unit.

Perform oil change every 100.000 miles

(160.000) km or once a year, whichever occurs first.

Vehicles that operate on the highway or off road in severe applications, using the maximum permitted load, should make the oil change in intervals of 25.000 to 31.000 miles (40.000 to

50.000 km) or every six months, whichever occurs first.

Magnetic Plug

Meritor recommends the use of magnetic plugs for the axle oil draining port.

Important:

The magnetic plug loses its efficiency quickly when it accumulates too many metallic particles and, therefore, should be cleaned before this happens. After removal and cleaning, the plug can be reused. It is recommended that this procedure be practiced once or more within the oil change period.

Changing Periods

New or Reconditioned Units

During the initial period (break-in), perform the differential oil change from 1.250 to 3.100 miles

(2.000 to 5.000 km). This initial oil change is recommended to ensure the removal of metallic particles typically generated in bigger amounts during this phase.

After the break-in period

Vehicles that operate primarily on the highway, with workloads below its maximum permitted load.


Tightening Torques


Instruction

Speed Changing Mechanism Operation

All MERITOR two-speed rear axles are extremely easy to operate.

To obtain a smooth and accurate engagement, use the sequences listed below:

1. CHANGE ONLY IN THE SHAFT:

A. From low speed (LS) to high speed (HS)

(AV)

Important

Do not shift the shaft from high to low speed

(HS to LS) when the vehicle is performing speeds which can drive the engine to revolutions higher than the maximum (governed).

If the shift system is triggered in this condition, the coupling is not complete until the vehicle speed drops to a speed corresponding to the maximum (governed) engine revolutions.

First, keep the throttle and lift the power button of the changing mechanism.

Then release the throttle or press the clutch pedal and wait a while to complete the engagement and re-accelerate.

B. From high speed (HS) to low speed (LS)

First, keep the throttle and push the power button of the changing mechanism.

Then release and press the accelerator as faster as possible, or press and release the clutch pedal quickly.

CAUTION

IF THE ACTIVATION IS DONE IN A DOW-

NHILL THE PROBLEM WILL BE MORE

CRITICAL, BECAUSE THE VEHICLE SPE-

ED DOES NOT REDUCE BUT INCREASES,

MAKING IMPOSSIBLE THE COUPLING IN

LS. IT CAN NOT EVEN RETURN TO HS, IF

THE SPEED GETS TOO HIGH.

IN THIS CASE, IMMEDIATELY ACTIVATE

THE TOP GEAR (THE LONGER ONE) OF

THE TRANSMISSION, FOR NOT STAYING IN

NEUTRAL.

2. SHIFT AND SHAFT COMBINED CHAN-

GING:

A. Top gear in the transmission = low speed in the shaft:

First, shift the gear normally. Then lower the power button of the changing mechanism shortly before releasing the clutch pedal.

B. Lower gear in the transmission + low speed in the shaft:

First, keep the throttle and lift the power button of the changing mechanism.

Then, shift the gear normally.


Always use Technical Manuals of...


Always use original parts

For more details, see the Spare Parts Catalog

Customer service

0800 55 55 30

Purchase the CD-ROM failure analysis of components of the axis traction

Customer Service

Av. João Batista, 825 - Osasco - SP - 06097-105

Tel. 0800 55 55 30

AfterMarket (Peças de Reposição)

Rod. Presidente Castelo Branco Km 30,5 - n° 11.250 - Barueri - SP - 06421-400

Tel. 0800 55 55 30 www.meritor.com/brasil

No results