Note 1: Adjustment ring selection is only required when replacing one of the following parts: clutch or gearbox housing, differential housing, or differential bearings.
Note 2: Differential bearings should be preloaded with 0.15-0.35mm. The preload is ensured by selecting the thickness of the adjusting ring from those supplied as spare parts. The adjusting ring is installed in the socket of the gearbox housing under the outer ring of the differential bearing.
1. Insert a 1.25mm set ring into the gearbox housing housing under the differential bearing.
2. Press the differential bearing outer race into the gearbox housing.
3. Press the differential bearing outer race into the clutch housing housing.
4. Install the differential into the gearbox housing.
5. Install the seal.
6. Install the clutch housing to the transmission housing.
7. Tighten three crankcase mounting nuts equidistant from each other to a torque of 25.0 Nm (2.5 kgf·m).
8. Rotate the differential a few turns to self-align the bearings.
9. Install a base plate of the correct diameter on the end of the differential flange on the clutch housing side.
10. Put the indicator on the stand. Mount the indicator leg on the base plate with a preload of 1 mm.
11. Applying force from below, move the differential up to the stop without turning the differential around the axis.
12. Measure the amount of axial movement of the differential by reading the indicator. Calculate the required differential bearing shim thickness using the formula:
T = S + C + Y, where:
T is the required thickness of the adjusting ring, mm;
S is the measured value of the axial displacement of the differential, mm;
C - the value of the preload of the differential bearings, equal to 0.25 mm;
Y is the thickness of the adjusting ring, equal to 1.25 mm.
Select an adjusting ring with a calculated thickness of T±0.1 mm from those supplied as spare parts.
Calculation example: The value of the axial clearance S according to the indicator is 0.95 mm. We substitute this value into the formula, as well as the value of the bearing preload C=0.25 mm and the thickness of the adjusting ring Y=1.25 mm:
T = 0.95 + 0.25 + 1.25=2.45 mm.
Thus, the thickness of the adjusting ring should be 2.45±0.1 mm.
13. Install the selected adjusting ring into the housing of the gearbox housing and press in the outer race of the differential bearing. Next, assemble the gearbox in the order indicated in subsection 12.12.
14. After bolting the clutch and gearbox housings, check that the differential must turn freely and have no axial play.