Mahindra 3535, Service Manual

Page: 219 / 368

E-42 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Differential
12. ADJUSTMENTS
a. ADJUSTING THE SPLINE SHAFT BEARING
PRE-LOAD
1. Using a standard spacer measuring 0.2" on the
machined flat surfaces, assemble the spline
shaft into transmission case with low gear,
bush, collar and sleeve, medium gear assembly,
high gear and high gear bush.
2. Install tail bearing using either hydraulic press
or by induction heating.
3. Install gear 4WD input and secure assembly
with two lock nut and lock washers.
NOTE: If the differential is in position,
sufficient shim thickness must be
installed to ensure that the end float
of the spline shaft is not restricted by
the bevel gear. If the differential is not
in position, no shim should be used.
4. Install a dial indicator on the transmissions case
with the stylus bearing against the machined
face of the pinion.
5. Determine the end float of the spline shaft by
pushing the spline shaft firmly to the rear and
noting the reading, then pulling the shaft
forward and noting the reading.
NOTE (1) : Several measurements should be
taken, rotating the shaft at each reading.
(2) : Ensure that the extreme length of
travel is reached in each direction.
6. As the pre-load on the spline shaft rear
bearings is the equivalent of 0.005" tight, the
thickness of spacer and shims is determined
as in the following example.
End float measured..................... 0.003"
Fixed pre-load.............................. 0.005"
Therefore :-
Amount of end float to be removed is
0.007" + 0.005" = 0.008"
Standard spacer measures 0.2"
Therefore :
Thickness of spacer and shims to be installed
is 0.2" - 0.008" = 0.1992".
NOTE: The average thickness of the spacer is
0.203" and graded spacers are available
in thickness range of 0.192" to 0.214"
in increment of 0.001".
7. Remove the lock nut and press the shaft to
take out bearing and spacer out.
8. Remove the standard spacer from the shaft
and install the correct thickness spacer.
9. Assemble gear 4WD, lock nut and lock washer,
then secure assembly by tightening the lock
nut to the specified torque.
10. Major preload of spline shaft bearing by
rotating string wrapping around coupling
high-low-medium using spring balance.
11. Change the graded spacer if specified preload
is not achieved.