Daewoo B20S-2, Specifications Systems Operation Testing & Adjusting Disassembly & Assembly

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Power Train Testing And Adjusting
1. If the original bevel gear and pinion set is to be
used again, measure old shim pack (2) and make
a new shim pack the same thickness. If a new
bevel gear and pinion set is used, refer to the
Pinion Shim Chart for the amount that the original
shim pack should be changed.
If three or more shims are used, the smaller shims
are to be put in the center of the shim pack.
EXAMPLE: If the old pinion has a mark of (+.06) and
the new pinion has a mark of (-.08) add 0.14 mm
(0.006 in.) shims to the original shim thickness.
2. Install bearing cups (3) and (4) with new shim
pack (2) behind bearing cup (3). Install bearing
cone (5) on pinion shaft (6).
3. Put the pinion shaft assembly into the housing and
install bearing cone (7) and nut (8). Tighten nut (8)
to a torque of 15 to 34 N¥m (11 to 25 lb¥ft) while
rotating the pinion.
4. Measure the distance from the centerline of the
differential bearing bores to the end of the pinion
and determine the amount of shims needed
behind bearing cup (3). See Pinion Depth Check.
5. Remove bearing cup (3) and add or remove the
required shims. Reinstall bearing cup (3).
6. Recheck pinion depth. The measured pinion depth
must be within 0.03 mm (0.001 in.) of the required
pinion depth.
7. After the pinion depth is correct, remove
Pinion Depth Gauge and the pinion shaft. Put ring
(9) on the pinion shaft and put gear (10) in position
in the housing. [NOTE: Side of gear (10) with
recessed hub must be installed next to ring (9)].
Put the pinion shaft in the housing and through
gear (10). Install ring (11) on pinion shaft (6).
8. Set pinion bearing preload. See Pinion Bearing
Adjustment.
9. Recheck pinion depth.
10. After pinion bearing preload and pinion depth are
correct, bend a tab on the lockwasher into a slot
of nut (8) to lock it in position.
23
PINION SHIM CHART
New Pinion Marking
+.10 +.08 +.06 +.04 +.02 0 -.02 -.04 -.06 -.08 -.10
+.10 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm +0.18mm +0.20mm
(0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.) (0.006 in.) (0.007 in.) (0.008 in.)
+.08 -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm +0.18mm
(0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.) (0.006 in.) (0.007 in.)
+.06 -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm
(0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.) (0.006 in.)
+.04 -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm
(0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.)
+.02 -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm
(0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.)
0 -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm
(0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.)
-.02 -.0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm
(0.005 in.) (0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.)
-.04 -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm
(0.006 in.) (0.005 in.) (0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.) (0.002 in.)
-.06 -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm
(0.006 in.) (0.006 in.) (0.005 in.) (0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.) (0.002 in.)
-.08 -0.18mm -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm
(0.007 in.) (0.006 in.) (0.006 in.) (0.005 in.) (0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.) (0.001 in.)
-.10 -0.20mm -0.18mm -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0
(0.008 in.) (0.007 in.) (0.006 in.) (0.006 in.) (0.005 in.) (0.004 in.) (0.003 in.) (0.002 in.) (0.002 in.) (0.001 in.)
Old
Pinion
Marking