|
Replace differential gear ring gear (F23)
 Remove
| 1. |
Dismantle transmission
|
|
| 2. |
Determine setting of pressure collar and initial bearing stress
of differential gear
| • |
Remove tapered roller bearing from differential gear 
|
| • |
Measure and note down thickness of shim (2) on transmission
housing side
| – |
Remove shim
Note: The shim on the
transmission housing side (2) is used for setting the pressure
collar. The dimensions of the shims must be determined with a
micrometer as there is no marking on them
|
|
| • |
Measure and note down thickness of shim (1) on clutch housing
side
| – |
Remove shim
Note: The shim on the
clutch housing side (1) is used for setting the initial tension of
the differential gear tapered roller bearing.
|
|
|
|
| 3. |
Determine the distance (I) from the outside of the ring gear to
the bearing seating on the differential gear
| • |
Use a standard commercial digital depth micrometer
Note: Micrometer range
at least 250 mm, 0.01 mm graduations
|
| • |
Perform measurement 3 times - space measuring points evenly
around ring gear (arrows)
|
| • |
Add all measured values together
|
| • |
Divide by the number of measurements
|
| • |
Note down the average for the old ring gear
Note: The table below
is a specimen calculation. You can enter the actual measurement
results in the blank column on the right of the printout and
perform the calculation there.
|
Example
|
Your values
|
|
1st measurement
|
15.02mm
|
+
|
1st measurement
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|
|
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mm
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+
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2nd measurement
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15.06mm
|
+
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2nd measurement
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mm
|
+
|
|
3rd measurement
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15.05mm
|
=
|
3rd measurement
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mm
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=
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Total
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45.13mm
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:3=
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Total
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|
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mm
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:3=
|
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Average
|
15.04mm
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Average
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mm
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| 4. |
Remove the ring gear from the differential
| • |
Clamp differential gear (1) in a vice with protective jaws
|
| • |
Unscrew 10x bolt (arrow)
|
| • |
Drive ring gear (2) off differential gear with plastic
hammer
|
| • |
Clean differential gear and inspect for damage
|
| • |
If necessary: replace differential gear
|
|
|
|
| 5. |
Install new ring gear in differential
| • |
Place the ring gear (1) on the differential gear (2)
|
| • |
Screw in 2x bolt (3) to secure
|
| • |
Drive ring gear onto differential gear with plastic hammer
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|
|
|
| 6. |
Insert 10x new screws (arrow)
| • |
Screw in 10x bolts with locking compound
|
| • |
Tighten 10 bolts evenly in crosswise formation 95 Nm
|
|
|
| 7. |
Determine the distance (I) from the outside of the new ring
gear to the bearing seating on the differential gear
| • |
Use a standard commercial digital depth micrometer
Note: Micrometer range
at least 250 mm, 0.01 mm graduations
|
| • |
Perform measurement 3 times - space measuring points evenly
around ring gear (arrows)
|
| • |
Add all measured values together
|
| • |
Divide by the number of measurements
|
| • |
Note down the average for the new ring gear
Note: The table below
is a specimen calculation. You can enter the actual measurement
results in the blank column on the right of the printout and
perform the calculation there.
|
Example
|
Your values for new ring gear
|
|
1st measurement
|
15.02mm
|
+
|
1st measurement
|
Your values
|
|
|
|
|
|
|
mm
|
+
|
|
2nd measurement
|
15.06mm
|
+
|
2nd measurement
|
|
|
|
|
|
|
|
mm
|
+
|
|
3rd measurement
|
15.05mm
|
=
|
3rd measurement
|
|
|
|
|
|
|
|
mm
|
=
|
|
Total
|
45.13mm
|
:3=
|
|
Total
|
|
|
|
|
|
|
mm
|
:3=
|
|
Average
|
15.04mm
|
|
|
Average
|
|
|
|
|
|
|
mm
|
|
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|
|
| 8. |
Determine pressure collar setting for new ring gear
| • |
Calculate the difference between the averages
| – |
Subtract average noted down for old ring gear from average
noted down for new ring gear
Note: If the difference
exceeds +0.02/-0.06mm, the pressure collar must be adjusted. If it
is less, the old shims can be re-used.
Note: The table below
is a specimen calculation. You can enter the actual measurement
results in the blank column on the right of the printout and
perform the calculation there.
|
Average
|
New ring gear
|
15.16mm
|
-
|
|
-
|
|
Average
|
Old ring gear
|
15.04mm
|
=
|
|
=
|
|
Difference in dimensions
|
+ 0.12 mm
|
|
|
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|
| 9. |
Insert 2x shim (1, 4)
Important: Make sure that the
correct shims are fitted on the clutch housing side and the
transmission housing side
|
| • |
If necessary, reset pressure collar
| – |
Determine the thickness of the new shims and insert them
Note: If the difference
between the dimensions is positive, choose a shim (4) that is the
same dimension thicker than the old one. If the difference is
negative, a correspondingly thinner shim must be used. The total
thickness of both shims must remain constant as this determines the
prestressing of the differential gear tapered roller bearing.
Therefore if a thicker shim (4) is used on the transmission housing
side, fit a clutch housing side shim (1) that is thinner by the
same amount. If a thinner shim is used on the transmission housing
side a correspondingly thicker shim must be installed on the clutch
housing side.
Note: The shims can be
obtained from "Aftersales". The thickness of the shims (2) must be
determined with a micrometer (3) as there is no marking on them
Note: The table below
contains a few examples from the range of shims that can be
supplied. When adjusting, the shims must be selected to achieve the
smallest tolerance possible. Undamaged used shims can be
re-used.
|
Difference in dimensions
|
Shim (on transmission housing side)
|
Shim (on clutch housing side)
|
|
- 0.25 mm
|
old
|
0.90mm
|
new
|
0.65 mm
|
old
|
0.75mm
|
new
|
1.00mm
|
|
+ 0.20 mm
|
old
|
0.90mm
|
new
|
1.10 mm
|
old
|
0.75mm
|
new
|
0.55mm
|
|
+ 0.13mm
|
old
|
0.90mm
|
new
|
1.05 mm
|
old
|
0.75mm
|
new
|
0.60mm
|
|
+ 0.12 mm
|
old
|
0.90mm
|
new
|
1.00mm
|
old
|
0.75mm
|
new
|
0.65 mm
|
|
|
|
|
Important: If the inner rings of
the differential gear tapered roller bearing are replaced, the
outer rings must be replaced too.
|
| 10. |
When the differential gear tapered roller bearing is being
replaced, remove 2 differential gear tapered roller bearing outer
rings from the clutch housing and the transmission housing
|
Install
| 11. |
Install differential gear tapered roller bearing
|
| 12. |
Assemble transmission
|
|
