Press, if necessary, the sprocket of the pulse sensor.
Remove the tapered roller bearing with a puller.
Remove driven bevel gear.
Press in the new tapered roller bearing with the bushing.
Remove the seals from both bearing caps.
Press out the outer races of the bearings with a tool and a removable sprocket.
Attention: The detachable sprocket must lock into the bearing.
Press in the new outer bearing races with the tool.
If only the differential bearings are replaced, the bevel gear may remain installed and the differential box inserted without the driven bevel gear to determine the size of the wear washers.
Lubricate the bearings well with oil and let it drain.
Fit the side bearing caps with your wear washers, but first without the rings.
Tighten the bearing cap bolts on the driven gear side. Observe the installation position of the cover.
The expansion hole in the installation position must always point upwards.
Axial stress of differential box (5000 N) can be determined in terms of the torque resistance force.
Tighten the second bearing cap bolts so that the differential can rotate easily.
On the side tightened with a certain force, put on the flange and fix it with a bracket with a welded nut. Use a dynamometer to measure the torque resistance at 50 rpm.
Turning force depends on the bearing (manufacturer) and is 1.24-2.8 Nm.
If, despite the caps being fitted, the required force is not obtained, thinner wear washers must be installed against the differential gear until the prescribed force is reached.
The opposite should be done if the force is already reached with the caps loose.
Remove the differential box, position the side covers and matched wear washers.
Install the driven bevel gear.
Insert two threaded guide pins diagonally into the threads of the driven gear.
Heat the driven gear to 100°C and check with a thermocouple.
Install the driven gear, insert the bolts. Observe tightening torque.
Tighten the bolts crosswise.
Install the driven gear differential.
Install the side cover as indicated with the appropriate bolt.
Adjust the backlash in the meshing of the gears using the tool. It should be 0.06-0.13.
Check the meshing pattern of the main gear teeth. To do this, lubricate the driven bevel gear with lead oxide to determine the contact, and rotate in both directions under load.
Determining the engagement of the final drive gears by the contact patch
1 - the height of the teeth on the outer diameter is greater than on the inner one (arrows);
2 - type of spot - load;
3 - clearance in engagement;
4 - type of spot;
5 - direction of rotation;
6 - no load;
7 - with load;
8 - no load;
9 - very small;
10 - correct;
11 - correct;
12 - wrong;
13 - back.
The side clearance can be adjusted by changing the thickness of both wear washers.
The total thickness of the wear washers cannot be changed. If one washer is made thinner, then the other should become the same amount thicker.
An axial shift of the driven bevel gear by 0.01 mm means a change in backlash by 0.0076 mm.
Insert the seals and o-rings into the side covers as described earlier.
Elements of the main gear of the rear axle
1 - axis of the differential;
2 - conical satellites;
3 - gears of semiaxes;
4 - pressure ring;
5 - internal lamellas;
6 - external lamellas 1.9 mm, 2.0 mm, 2.1 mm;
7 - disc spring;
8 - adjusting washer;
9 - Belleville spring;
10 - cylindrical bolt;
11 - housing cover;
12 - differential housing;
13 - limited slip differential.