6.

REAR AXLE

5-5-k. REMOVING AND INSTALLING THE DIFFERENTIAL CARRIER ASSEMBLY

1. Removing the differential carrier assembly
1) Drain the oil from the axle.
2) Secure the shift lever of the cross diff. lock in disengaged position.
3) Remove the axle shafts as described in Section "5-5-f"
4) Remove the hex. flanged bolts attaching the differential carrier assembly to the axle housing and
by 2 off M14x1.5 bolts driven into the two threaded bores in the flange of the differential carrier pull
the differential carrier assembly out of the axle housing.

2. Installing the differential carrier assembly

1) Before reinstalling the differential carrier assembly perform repair of the diff. lock shifter shaft(19
in Fig. RA2600 of Section "5-5-zb") and installation of clutch sleeve to the axle-shaft, as described
in the Section "REPAIRING THE DIFFERENTIAL LOCK", because after installation of the differ-
ential carrier assembly these are not accessible.
2) As described in the "GENERAL INSTRUCTIONS" apply DOW Corning No. 732 sealant to flange
of the axle body and to connecting flange of the carrier I.
3) Install one stud bolt to two opposite bores in the axle body, then fit the carrier assembly into the
axle housing and secure by hex. bolts coated with sealant LOCTITE 242.
4) Tighten the bolts diagonally to (16~18kgf.m) torque.
5) Following this install the axle shafts as described in Section "5-5-f".

5-5-l. REMOVING AND INSTALLING THE COMPANION FLANGES AND THE COVER,
REPLACING THE OIL SEALS IN THE COVER
1. Remove the self-lock nut(1) by means of wrench adapter then pull the companion flange off by tools
multipurpose step plate, puller, spindle, and M12 nuts.

2. Replacing the sealing rings in the cover

Back out the hex. bolts(6) and remove the cover(5) and the shims(67).
By means of the tools shown remove the used sealing rings(4) from the cover.

Drive mandrel
(Special tool: TD37030)

Step plate

RA2211

82
 6. REAR AXLE

Drive mandrel

(Driving the oil seal into the cover)

RA2221

3) By means of tool shown drive the new oil seal into the cover(5) to flush with side of the cover.
4) Apply LZS-2 grease to between the sealing lip and dust protection edge of the oil seal.

3. Installing the cover

1) When installing the cover adjust the axial play of the input shaft as described in the Section "5-5-t",
then as described in the "GENERAL INSTRUCTIONS" apply DOW Corning No. 732 sealant to the
protruding corner surface of the outer taper roller bearing on the input shaft.
2) Aligning the bores install the necessary shim pack(67) and the cover subassembled with sealing
rings. Attach to the carrier III by means of lock washers(7) and hex. bolts(6). Tighten the bolts to
60~80 Nm torque.

4. Installing the companion flange

1) Fitting to splines of the input shaft and by means of press 4642-00817(as shown in Fig. RA2491
of Section "5-5-y") drive on the companion flange I(3) until bottoms out, making sure not to dam-
age the sealing rings.
2) Install the washer(2) and the self-lock flanged nut(1). By means of the wrench adapter tighten the
nut to 800~1,000 Nm torque.
3) Following this moving the input shaft to axial direction measure the axial play by means of dial
indicator equipped with magmetic stand. Turning the companion flange by pry perform measure-
ment at three places in even pitch.
4) The axial play should be between 0.05~0.15 mm. Adjust this value, if required, by selecting the
proper shim pack(67).
5) After adjusting the proper axial play no jamming or uneven rotation is permitted.

83
6. REAR AXLE

5-5-m. REMOVING AND INSTALLING THE THRU-DRIVE SHAFT

1. Removing the thru-drive shaft

Thru-drive shaft puller

Pulling out the thru-drive shaft

RA2231

1) As described in the Section "5-5-l". remove the self-lock nut(1) and the companion flange II(105)
from the thru-drive shaft(94).
2) By means of a simple pry remove the sealing rings(4).
3) Remove the snap ring(100) and the shim(99).
4) By means of the device shown remove the thru-drive shaft together with the deep-groove ball
bearing(98). Secure the device to the thru-drive shaft by means of the self-lock nut(1) as shown
in Fig. RA2231.
5) If replacement of the deep-groove ball bearing(98) is required, properly back-up the bearing and
tap the thru-drive shaft out of the bearing.

2. Installing the thru-drive shaft

Drive sleeve

Installing the thru-drive shaft

RA2241

84
 6. REAR AXLE

1) Heat up the deep-groove ball bearing to 80~100ºC and by means of tool 4905-00156 install to the
thru-drive shaft to bottom out against the shoulder ring.
2) Position the subassembled thru-drive shaft to the axle housing, the aligning its splines to those of
the gear I(91) dirve the deep-groove ball bearing together with the shaft to place until the bearing
bottoms out against its seat. For driving in use the same tool as above(see Fig. RA2241).

3. Driving in the sealing ring

Drive sleeve

RA2251

1) Apply thin coat of LZS-2 grease to between the sealing lip and the dust protection edge of the
sealing ring.
2) As described in the Section "5-5-l". install the companion flange II(105) to the shaft-end, position
the washer and secure by self-lock nut tightened to 540~590 Nm torque. Rotate the thru-drive
shaft and check for even run, free of jamming and jerks.

5-5-n. REMOVING THE INPUT SHAFT AND THE DIFERENTIAL CARRIER III
1. After removing the companion flange I(3) and the cover(5) remove the hex. flanged bolts(14) from
the outer flange of the differential carrier III(45) and separate the diff. carrier III from the diff. carrier
II.
2. Withdraw the carrier III(45) together with the input shaft(68) and the toothed hub(69).
3. Remove the differential side gear II(85) assembled with pinion drive spur gear(82), the differential
and the differential side gear I(91) assembled with inner race of the taper roller bearing.32214 A
4. After backing out the 2 off M8x15 bolts remove the inter-axle differential lock actuating pneumatic
chamber and unscrew the shift bar(79) from threaded bore of the shift yoke(78).
5. Pull the toothed hub(69) together with shift yoke(78) from the input shaft(68) and also remove the
spring(80) set free.
6. Properly backing up the carrier III tap the input shaft out of the inner race of taper roller bearing(51).

85
6. REAR AXLE

Step plate

Drive mandrel
(Special tool: TD37030)

Driving out the taper roller bearing

RA2261

7. From the carrier III remove the remained taper roller bearing by means of the tools shown(see Fig.
RA2261).

5-5-o. REMOVING AND INSTALLING THE CROSS DIFFERENTIAL, ADJUSTING THE BACK-
LASH AND CONTACT PATTERN
1. Removing the differential

Claw spanner

Removing the bearing adjusters

RA2271

1) Remove the snap ring(36 in Fig. RA2191 a of Section "5-5-j"), the backing ring(35) then pull out the
set free lock clutch gear(34).
2) Back out the hex. bolt(22), remove the lock plates(23) and the tab lock plate(21), then remove the
bearing adjusters(20 and 33) from both sides by means of the tool shown(see Fig. RA2271).
3) After removing the bearing adjusters back out the hex. bolts(41) and remove the bearing shack-
les(40). Following this remove the differential from the differential carrier and remove the outer race
of the taper roller bearings(19 and 32).

86
 6. REAR AXLE

2. Installing the differential

1) Reinstall the differential only after installing the carrier II and adjusting the axis distance.
2) Fit the assembled differential together with outer races of the taper roller bearings(19 and 32) into
the carrier. Position the bearing shackles(40) to the original place, install the bearing adjusters
hand-tight and secure by hex. bolts(41) and washers(42). Tighten the bolts to 333~353 Nm torque.

3. Adjusting the backlash and the bearing preload

Backlash calibrate

Checking the backlash

RA2281

1) By means of the bearing adjusters set the drive pinion to gear backlash(at GLEASON toothing) to
0.25~0.33 mm.
2) Install the differential bearings(19 and 32) without clearance maintaining the backlash.
3) Locking the drive pinion measure the backlash at four places diagonally on the rig gear toothing,
perpendicularly to the tooth surface by means of the backlash checking device.
4) It is important that while the bearing is adjusted, the ring gear has to be kept revolving, this will
assure seating of the taper rollers in the bearings. If setting is made in stationary position, the
bearings can get stressed or the rolling bodies can get jammed. The bearings set in this way
release during revolution.
5) Install the differential taper roller bearings without clearance. At the supporting flange on the two
+0.03
legs of the carrier bearing support obtain the dimension 407 mm.0 This dimension is adjusted by
simultaneously adjusting the bearing adjusters so, the checking(adjusting ring M1 shall fit with
drag.)
6) After adjusting the backlash and the bearing preload check the contact pattern as follows.

4. Adjusting the contact pattern

1) Apply indicator paint to opposite teeth pairs of the ring gear at 4 places of 90° pitch and one tooth
of the drive pinion.
2) Rotate the drive pinion to both directions for approx. 15 sec, while braking the ring gear by a piece
of wood.

87
6. REAR AXLE

D
D = Large diameter
1 1. Proper contact
2. Too deep contact
3. Too high contact

Contact pattern
RA2291

3) If the contact pattern corresponds to detail 1 of the Fig.RA2291, the pinion-ring gear pair is in-
stalled properly.
4) Practically the perfect contact pattern shown in the figure cannot be obtained, but is important that
the pattern shall nowhere touch the edge of the tooth surface.
5) In case of KLINGELNBERG TOOTHING the contact pattern is located symmetrically in the center
of the ring gear tooth length. In case of GLEASON toothing the contact pattern is shifted along the
tooth length toward the small diameter of the ring gear.

The contact pattern extends over the dedendum:

If the contact pattern extends over the dedendum as shown in detail 2 of Fig. RA2291. increase
the "AXIS DISTANCE" as required by increasing the thicknness of shim pack, simultaneously
reduce the increased backlash by displacing the ring gear to obtainn the contact pattern shown in
detail 1 of Fig. RA2291.

The contact pattern extends over the addendum:

If the contact pattern extends over the addendum as shown in detail 3 of Fig. RA2291. reduce the
"AXIS DISTANCE" as required by reducing the thickmess of shim pack(13), simultaneously in-
crease the reduced backlash by displacing the ring gear to obtain the contact pattern shown in
detail 1 of Fig. RA2291.
During drive the ratation should be smooth and noiseless.
6) After each contact pattern adjustment measure the backlash, readjust the bearing preload and
+0.03
check the dimension 407 0 mm on the supperting flange.
7) When the adjustment and the operation is proper, remove the carrier II assembled with drive pin-
ion and according to the "GENERAL INSTRUCTIONS" apply DOW CORNING No. 732 sealant to
the inner flange, then fit back the diff. carrier II and secure by hex. flanged bolts(14) coated with
LOCTITE 242. By means of wrench extension 4905-00022/M1 diagonally tighten the bolts to
(9~10kgf.m) torque.
+0.03
8) Maintaining the previously adjusted 407 0 mm leg dimension secure the tab lock plates(21) by
the hex. bolts(22). Tighten the bolts to (1.5~2kgf.m) and secure by folding the cornners of the lock
plates(21) to flats of the bolts.

88
 6. REAR AXLE

9) Fit the lock clutch gear(34) to splines of the differential case, install the backing ring(35) and se-
cure by snap ring(36).
10) Attach the oil baffle plate(97) to relevant bores in the diff. carrier by 2 off lock washers(95) and
hex. bolts(96). Tighten the bolts to 30~40 Nm torque.

5-5-p. DISASSEMBLING AND REASSEMBLING THE DIFFERENTIAL

1. Disassembling

Ring Bolt
Multipurpose step plate
Puller spindle
Ring puller
Bolt puller
Plug

Pulling off the inner race of taper roller bearings

RA2301

1) Pull the inner race of the taper roller bearings(19 and 32) from the removed differential.
2) For disassembling the differential case remove the hex. bolts(25) clamping the case halves(24
and 31) together and separate the case halves.
3) Remove the cross(28) together with the differential pinions(29) and shims(30) as well as the dif-
ferential side gears(27) and the spacers(26).
4) Replace the ring gear ONLY together with the matched drive pinion.
5) The match-marks are stamped to one end of the drive pinion and to one tooth end on the outer
taper surface of the ring gear.
6) The marks contain the identification number of the matched pinion and ring gear as well as thevalue
of deviation from the theoretical distance measured between the drive pinion face and the ring
gear centerline, ie. the "Axis distance", in true to sense.
Eg. : 1225+0.032

89
6. REAR AXLE

2. Reassembling

Service mandrel

Assembling and checking the differential

RA2311

1) Pull the flanged differential case half(31) over the lower service mandrel(Fig. RA2311). Insert the
spacers(26) and the differential side gear(27), as well as the differential cross(28) subassembled
with shims(30) and differential pinions(29), then insert the other differential side gear and the spacer.
2) Aligning the bores and the factory match-marks fit the differential case halves together and secure
by the clamp bolts(25). By means of the upper service mandrel lock the differential and tighten the
clamp bolts to (7~8kgf.m) Nm torque.
3) Remove the upper service mandrel and rotate the differential on the lower mandrel.
4) No jamming or jerk is permitted, the differential should roll freely and evenly.

Pilot bolt

Pulling on the drive gear

RA2321

90
 6. REAR AXLE

5) Fit the drive gear to the subassembled differential and by means of four M18 small-headed bolts
of at least 80 mm length and nuts with washers pull the drive gear to the differential to bottom out.
6) After this remove the small-headed bolts, install the original bolts(39) and tighten the self-lock
nuts(38) attaching the drive gear to the differential to 29~32kgf.m torque.

Press head
Plug
Head bolt

Pressing on the ring gear and the inner race of the lock side taper roller bearing
RA2331

7) By means of press head arranged from items 7, 8 and 9 of the shown device press the inner race
of the taper roller bearing to the differential lock side.

Press head

Pressing on the inner race of the raper roller bearing

RA2341

8) Turn the differential case over and by means of the press head shown press the inner race of the
taper roller bearing to the other side.

91
6. REAR AXLE

5-5-q. REMOVING AND INSTALLING THE DIFFERENTIAL CARRIER II, ADJUSTING THE
AXIS DISTANCE

1. Removing the differential carrier II

1) If the drive pinion(16) or its bearings are to be replaced remove the diff. carrier II from the diff.
carrier I(15).
2) By means of the wrench extension 4905-00022/M1 remove the hex. flanged bolts(14) from the
inner flange.
3) Following this separate the diff. carrier II from the diff. carrier I and lift out together with the drive
pinion and the driven gear(50). Remove the shims(13).

2. Installing the differential carrier II. to the differential carrier I

After reassembling the carrier II and adjusting the specified bearing preload adjust the axis
distance(after removing the differential).

3. Adjusting the axis distance, installing the differential carrier II

1) For purpose of piloting screw M12 stud bolts to two opposite bores in flange of the carrier I(15).
Position the shims(13) necessary for adjusting the ring gear - pinion contact pattern over these
stud bolts so, the extreme two ones shall be the thicker. Use maximum 4 pcs from the shims.
2) Fit the carrier II subassembled with drive pinion into the ø240 bore of the carrier I and over the ø8
dowel pin, then at two opposite bores provisionally secure by hex. flanged bolts tightened to
(9~10kgf.m) torque.
3) Accordings to Fig. RA2521 of Section "5-5-z". install the axis distance adjusting device. Set its dial
indicator on the accessory of measuring pin the device at 99 mm datum to zero, then measure the
axis distance and check if it is identical to that written into end of the drive pinion. Incase of identity
the adjustment is proper, otherwise perform correction by replacing the shims(13) to obtain the
given value. Permitted deveation is ±0.025 mm.
Eg. : If the axis distance deviation stated on the drive pinion is +0.22, the value "B" to be adjusted
is 99.22±0.025 mm.
4) For measuring the axis distance refer to Fig. RA2521 of Section "5-5-z".
After adjusting the axis distance reinstall the differential and adjust the contact pattern according
to the Section "5-5-o".

92
 6. REAR AXLE

5-5-r. DISASSEMBLING AND REASSEMBLING THE DIFFERENTIAL CARRIER II.

1. Disassembling the differential carrier II.

Press mandrel

Press mandrel

Pressing out the drive pinion

RA2351

1) By means of the press shown press the drive pinion out of the removed differential carrier II.
When pressing out the drive pinion the inner race of the inner taper roller bearing remains on the
pinion spindle.

Pulling off the inner race of the taper roller bearing

RA2361

2) Pull off the inner race of the taper roller bearing by means of the tools shown.
3) From the carrier II press out the cup of taper roller bearing(32312 B) by means of tools step plate
and drive mandrel(as shown in Fig. RA2521 of Section "5-5-z").
4) Turn the carrier II over and press out the cup of the inner taper roller bearing(32315 B) by means
of tools step plate and drive mandrel(as shown in Fig. RA2551 of Section "5-5-z").

93
6. REAR AXLE

Drive mandrel
(Special tool: TD37030)

Step plate

Driving out the outer race of the taper roller bearing

RA2371

5) If the inner taper roller bearing(32214 A) of the input shaft is to be replaced also, drive its cup out
of the carrier II by means of the tools shown.

2. Reassembling the differential carrier II

1) Before reassembling carefully check the removed parts and replace if required.

Drive mandrel
(Special tool: TD37030)

Drive mandrel set

Driving in the cup of taper roller bearing(32315 B) into the carrier II.
RA2381

2) First drive in the cup of the inner taper roller bearing(32315 B) by means of the tools shown, to
bottom out.

94
 6. REAR AXLE

Drive mandrel
(Special tool: TD37040)

Drive mandrel set

Driving in the cup of taper roller bearing(32312 B) into the carrier II

RA2391

3) Turn the carrier II over and by means of the tools shown drive in the cup of the outer taper roller
bearing to bottom out.
4) After subassembling the carrier II with the taper roller bearing cups adjust the specified bearing
preload.
5) The distance between the inner race of taper roller bearing(32312 B) and the distance sleeve may
vary from 13.96 to 15.00 mm. For selecting the proper distance ring pair(10) this distance should
be determined by measurement(X in Fig. RA2401).

Shaft

Handle
Dowel
Mounting bolt

Pin

Adjusting the bearing preload

RA2401

6) Position the inner race of the inner taper roller bearing(32315 B), the distance sleeve(11) and the
distance ring pair for filling the gap determined by measurement, then the subassembled bearing
cage, the inner race of the outer bearing(32312 B) and the driven gear(50) onto the adjusting
device. Position the washer(2) and screw on the self-lock nut(1).

95
6. REAR AXLE

7) Tighten the nut to (81~102kgf.m). After tightening the self-lock nut remove the part No. 17 of the
device and measure the rolling torque. Measure the rolling torque by means of cord wound around
the mantle of the driven gear(50) and fish-scale. The fish-scale shoyld read (12.3~3.7kgf.m)(which
corresponds to (0.25~0.4kgf.m) torque).
Incase of deviation from this value perform correction by changing the distance ring. If the rolling
torque is higher than specified use higher distance ring pair, while at lower torque use lower one.
8) When the adjustment is proper relocate the parts from the adjusting device to the drive pinion.
Make sure to install ONLY the parts used for adjustment over to the drive pinion.

5-5-s. INSTALLING THE DRIVE PINION

1. By means of tool drive sleeve press the inner race of the inner taper roller bearing(32315 B) onto the
drive pinion to bottom out(see Fig. RA2591 of Section "5-5-za").
2. Position the distance sleeve(11), the previously selected distance ring pair(10), the carrier II
subassembled with bearing outer races, them by means of press sleeve 4489-00006 press on the
inner race of taper-roller bearing(32312 B) to bottom out, taking care of proper connection of the
bearings. By means of press companion flange press on the driven gear(50), position the washer(2)
and screw on the self-lock nut(1).
3. Position the unit assembled in this way onto the adjusting device and tighten the self-lock nut to
(81~102kgf.m) torque.
Measure the rolling torque by fish-scale as described above and if required perform correction until
the specified value is obtained.

Securing the flanged lock nut

RA2411

4. After adjusting the specified bearing preload secure the flanged lock nut(52) by deforming into groove
of the drive pinion.

96
 6. REAR AXLE

5-5-t. INSTALLING THE INPUT SHAFT AND THE DIFFERENTIAL CARRIER III
• By means of the tools shown drive the cup of taper roller bearing(32214 A) into its seat to bottom out.

Step plate

Drive mandrel
(Special tool: TD37030)

Driving in the outer race of taper roller bearing(32214 A)

RA2421

Press

Driving on the inner race of taper roller bearing(32214 A)

RA2431

• By means of the tool shown drive the inner race of taper roller bearing(32214 A) onto the differential
side gear I (91) to bottom out.

97
6. REAR AXLE

Press head

Underlay

Driving the pinion drive spur gear onto the differential gear II
RA2441

• By means of the press head shown drive the pinion drive spur gear onto the differential side gear
II(85) to bottom out(see Fig. RA2441).
• Secure the pinion drive spur gear in place by installing the snap ring(81) to its groove.

1. Subassembling the intermediate differential case

1) Position the differential pinions(87) and the shims(86) to the cross(88) and insert this subassembled
unit into the previously separated differential case(89).
2) Aligning thd factory match-marks fit the differential case halves together, position the oil baffle
plate(90) to side of the diff. case and clamp the diff. case halves together by means of hex. bolts(93)
coated with LOCTITE 242 sealant. Diagonally tighten the clamp bolts to (6~8kgf.m) torque and
rotating the drive pinion check if the assembly is proper. During rotation no jamming may occur.

2. Subassembling the differential carrier III

1) Fit the toothed hub(69) to splines of the input shaft(68). The toothed hub should slide freely when
moving axially.
2) Put the input shaft together with toothed hub(69) sat to shift yoke(78) of the differential lock into
the carrier bore so, the threaded bore of the shift yoke shall align with actuating bore of the differ-
ential lock.
3) Put the spring(80) near the shift yoke and thru the carrier bore screw the shift bar(79) into threaded
bore in the shift yoke to bottom out and secure the spring.

98
 6. REAR AXLE

3. Installing the oil pump

1) As described in the "GENERAL INSTRUCTIONS" apply DOW Corning No. 732 sealant to seating
surface of the oil pump cover I (65) and to outer mantle of the cover II (64). Fit the oil pump
assembly into its bore and secure by means of hex. bolts with lock washers(66). Tighten the bolts
to 60~80 Nm torque.
2) Install the toothed disk(53) with woodruff key(60) to input shaft of the oil pump and screw on the
hex. nut with lock plate(57). Tighten the hex. nut to 37 Nm torque and secure by the tab lock plate.

4. Înstalling the differential carrier III

1) Secure the diff. carrier so, the outer flange or the carrier II shall face upward.
2) Install the differential gear subassembled with bearing inner race(as shown in Fig. RA2431), the
subassembled outer differential to outer race of the previously pressed in taper roller bearing(32214
A) so, the oil baffle side of the differential shall be on the side of taper roller bearing(32214 A) (ie.
on the lower side), then the pinion drive spur gear subassembled as per Fig. RA2441.
3) As described in the "GENERAL INSTRUCTIONS" apply DOW CORNING No. 732 sealant to flange
of the differential carrier.
4) After aligning the bores fit the subassembled diff. carrier III together with the input shaft by means
of dowel pin to the diff. carrier II. and the connected parts and clamp the carrier halves together
by means of hex. flanged bolts(14) coated with LOCTITE 242 sealant and tightened to 88~98 Nm
torque.

5. Installing the outer taper rolling bearing(32213 A) to the input shaft

Press sleeve

Driving on the inner race of taper roller bearing(32213 A)

RA2451

• Heat up the inner race of the taper roller bearing(32213 A) to 80~100°C, then by means of tools
shown drive onto the input shaft to bottom out against the shaft shoulder.

99
6. REAR AXLE

Press sleeve

Driving in the outer race of taper roller bearing(32213 A)

RA2461

1) Fit the cup of the previous bearing into the carrier III and drive in by means of the same tool so,
to fit to the bearing inner race on the input shaft without jamming or excessive play when rotating.
2) Following this, by moving in horizontal direction, check the lock shift bar(79) and shift yoke(78) for
operating properly without jamming. If trouble is experienced eliminate before going on with as-
sembly operations.

6. Adjusting and checking the axial play of the input shaft

1) Fit the cup of the taper roller bearing(32213 A) to the inner race, then rotating the input shaft
check for running free of jamming.
2) Measure the height of the bearing cup section protruding from the carrier III and mote the
measured value.
3) Measure the height of the inner bearing seat in the cover(5) subassembled with sealing ring(4) and
also note the result.
4) According to the measurement result select from the 7 different thickness shims(67) such an amount
- but maximum 5 off - which assures 0.05~0.15 mm axial play.
5) As described in the "5-5-b. GENERAL INSTRUCTIONS" apply DOW CORNING No. 732 sealant
to corner surface of the protruding bearing section, then install the previously selected shim
pack and the cover(5) subassembled with sealing ring. Aligning the bores attach to the
carrier III(45) by means of lock washers(7) and hex. bolts(6). Tighten the bolts to
(6~8kgf.m) torque.
6) Checking the axial play
After installing the cpmpanion flange(see Section "5-5-l") check the adjusted axial play by means
of magmetic stand dial indicator while moving the input shaft to axial direction.
Perform measurement at three even pitch places by turning the companion flange with pry.
7) During check an axial play of 0.05~0.15 mm should be obtained. In case of deviation adjust the
required value by means of shims(67).

100
 6. REAR AXLE

5-5-u. REPAIRING INSTALLING AND ADJUSTING THE INTER-AXLE DIFFERENTIAL LOCK

1. Repairing the pneumatic chamber

73

45°

70

71

19°

72

A : 7 mm

Luftkammer
RA2471

70. Chamber cover 71. Diaphragm

72. Clamp 73. Chamber housing

2. Assemling instruction for the clamp

The pneumatic chamber housing(73), the diaphragm(71) and the cover(70) to be axially compressed
in a device.
A = 7, 2-7, 5 mm
Nuts for the clamping bolts be tightened to 2.5 Nm torque the distance between the clamp ends-at
both ends-be egual.

3. Checking the pneumatic chamber after reassembling :

- Test pressure 10 bar
- The permitted max. travel is 18 mm

4. Installing the actuating pneumatic chamber and the electric indicator

1) As descrived in the "5-5-b. GENERAL INSTRUCTIONS" apply DOW Corning No. 732 sealant to
seating flange of the pneumatic chamber, then fit to the shift bar(79) and attach to the housing by
2 off M8x15 hex. bolts and lock washers. Tighten the bolts to 30~40 Nm torque.
2) Screw the threaded extension(77) coated with ATMOSIT to its bore to be leak-tight and punch
secure at three places. Insert the stem section of the pin(75) into bore of the threaded extension.
The pin should move in the bore free of jamming and should touch the shift yoke(78).
3) Screw the threaded extension(77) coated with ATMOSIT to its bore to be leak-tight and punch
secure at three places. Insert the stem section of the pin(75) into bore of the threaded extension.
The pin should move in the bore free of jamming and should touch the shift yoke(78).
4) Screw the lock nut(83) to the stop bolt(84) to bottom out against the threaded end, then screw the
stop bolt hand-tight into the housing bore.

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6. REAR AXLE

5. Adjusting the differential lock

1) Connect the air line and the electric wire.
2 2
2) Actuate the pneumatic chamber by means of 5 kg/cm(49 N/cm) pressure air, after then turn the
input(68) and thru-drive(94) shafts so, the clutch claws slide into one another. Following this care-
fully screw the stop bolt(84) coated with LOCTITE 242 until bottoms out against the shift bar(79),
then turn further by half turn and secure by lock nut(83) in this position.
3) After adjusting the stop bolt ckeck the differential lock and the electric indicator switch(76) for
proper operation. Perform readjustment if required. With lock in engaged position screw in the
press switch(76) until the pilot lamp goes on, then turn further by half turn and secure in this
position by lock nut. Following this check for proper operation by engaging and disengaging the
lock several times. Eliminate the trouble if experienced.

5-5-v. DISASSEMBLING AND REASSEMBLING THE OIL PUMP

1. Disassembling the oil pump

1) Remove the hex. bolts with lock washers(54) clamping the oil pump covers(64 and 65) and the oil
pump case(55), then remove the pump covers from the pump case.
2) After removing the cover pull the drive(61) and driven gears out of the oil pump case.
3) Tap or pull the used bushes out of the covers.
4) After backing out the flanged screw plug(63) the oil pressure control spring(59) and the steel ball(62)
can be removed from the pump cover II.

2. Reassembling the oil pump

1) Press the bushes into the covers to flush with the side surface.
2) Tap the lock pins into both sides of the pump case.
3) Insert the gear into relevant bores in the pump case, then fitting the covers to the gears and the
lock pins attach them to both sides of the pump case.
4) For reassembling the case and the cover use the matching sleeve.
5) Make sure the gears are installed to the relevant bores.
6) From the oil pump cover I side screw the hex. bolts with lock washers(54) thru the oil pump case(55)
and tighten to (1.3kgf.m) torque.
7) Punch secure the lock pin on the oil pump cover I(65) side against loosening.
8) Insert the steel ball(62) into the seat, position the oil pressure control spring(59) and secure by
flanged screw plug with sealing ring(56).
9) Install the other flanged screw plug with sealing ring(63), as well.

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 6. REAR AXLE

5-5-w. MAIN DIFFERENTIAL SECTIONAL VIEW

2 1
3

4
5
6 8 9
7 10
14 11
12

13

14
37
40 41 42 15

38
16
39
17

18
19

20

21

22
23

36

35 34 33 32 31 30 29 28 25 26 27 24

RA2481

103