Differential: 1 – speedometer drive pinion; 2 – satellite; 3 – axle gears; 4 – driven gear of the main transmission; 5 – satellite axis; 6 – differential housing; 7 – differential bearing
You will need:
- key "17"
- universal puller
- snap ring pliers
- bearing press mandrel
- beard
- hammer
Remove the differential from the gearbox (see subsection 11.1.2., operations 1–36).
One of the reasons for increased noise in the gearbox may be wear or breakage of differential parts.
Increased axial clearance of axle gears (more than 0.1 mm) can be eliminated by installing support washers of greater thickness.
For reference: the moment of resistance to differential rotation should not exceed 15 N/m (1.5 kgf/m).
Attention! The main gear pinions are selected in pairs at the manufacturer's plant based on noise and contact patch. Therefore, when replacing the driven pinion, also replace the driving pinion (they are sold in pairs). The driven gear is marked with the number of teeth of the driven/driven gear. To check, count the number of teeth of the drive gear.
Caution! When pressing with a puller, bearings can be damaged. Therefore, remove bearings only if replacement is necessary.
Attention! If during the gearbox repair process at least one of the following parts was replaced: clutch housing or gearbox housing, differential housing or differential bearings, then it is necessary to select a differential bearing adjusting ring (see subsection 11.1.7.).
1. Remove the retaining ring from the satellite shaft.
2. Using a punch, knock the satellite axle out of the differential housing.
3. By turning the satellites in the differential housing by 90°...
4....remove both satellites from the housing.
5. Remove the axle gear from the housing and...
6....a support washer installed underneath it.
7. Remove the second axle gear together with the washer.
8. Inspect the working surfaces of the satellites and their axles, the axle gears and the spherical surfaces of the differential housing that contact them. Remove minor irregularities using fine-grained sandpaper. Replace parts with significant defects.
9. Assemble the differential in the reverse order of disassembly, after lubricating all parts with transmission oil.
10. If there are chips, flaking or significant wear of the teeth, replace the gear. To do this...
11....unscrew the bolts securing the driven gear to the differential housing. We recommend removing the axle gears so that you can hold the differential housing with a mounting blade rather than clamping the gear in a vice.
12. Place the gear in the jaws of a vice and press the differential housing out of the driven gear.
13. Install the driven gear on the differential housing in the reverse order of removal. The tooth markings on the gear should be facing outward. Tighten the gear bolts evenly crosswise.
14. If there are cavities on the treads and rolling elements, traces of rolling element indentation on the treads, or damage to the separators, the bearings must be replaced. To do this, use a puller to press them off the differential. In this case...
15....press the bearing on the speedometer drive gear side by the separator (to avoid damaging the gear). If there is an inner bearing race left on the differential case, knock it off with a chisel or saw it off.
16. Press the new bearings in until they stop using a suitable mandrel, applying force only to the inner bearing races.
17. Press out the outer bearing rings from the gearbox and clutch housings using a special puller. If there is no puller, carefully press out the axle shaft seals first (for more details, see subsection 11.1.9.). Then...
18....from the outside of the crankcases, use a punch to press out the outer bearing rings.
19. There may be an adjusting ring under the ring installed in the gearbox housing, which must be re-fitted before pressing in new rings (see subsection 11.1.7.).
20. Press the new rings into the housings until they stop using a suitable mandrel. Do not change the rings relative to the bearings. If there is no mandrel, press the rings as far as possible using a flat metal plate, and then...
21....using a punch, press the rings down to the stop with even blows around the entire circumference.
22. To replace the speedometer drive gear, knock it off with a chisel or saw it off. Then press the bearing off with a puller, install the new gear and press the bearing in.