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Without Using Caliper

This process consists of a mathematical
calculation, and the result is sufficiently accurate
when the ring gear and drive pinion set is
replaced.

Other components that affect the proper position
of the drive pinion are the carrier, the drive pinion
bearing cage and the inner pinion bearing.
Therefore, if there is a need to change any of these
components, this mathematical process may be
used as a first attempt to select the shims to
properly adjust the tooth contact of the ring gear
and drive pinion.

Take note of the variation value (PV) on the
drive pinion to be replaced.

Observe the variation value (PV) on the new
drive pinion. If the value is the same as the
original drive pinion, the thickness of the
original shim pack must be maintained.

If the value is different, perform the following
calculations:

A. Measure and write down the thickness of

the original shim pack (pack thickness PT).

B. Check the variation value (PV) stamped on

the head of the original drive pinion. If the
number is (+), subtract this value from the
dimension of the thickness of the original
shim pack. If it is (–), add it.

The resulting value will establish a master
thickness for shim packs used for the
assembly of a drive pinion whose ND
dimension is equal to zero.

C. Take note of the value obtained in Step B to

use in the calculation of the thickness of the
shim pack for the new drive pinion.

D. Observe the variation value (PV) of the new

drive pinion. If the value is (+), add it to the
value obtained in Step C. If it is (–),
subtract it.

E. The final result obtained will establish the

thickness of the new shim pack to be used
in the installation of the new hypoid ring
gear/drive pinion set.

Example of Calculation “1”

Data:

PT (original pack). . . . . . . . . . . . . . . . . . . . . . . . . 0.09

PV (original drive pinion) . . . . . . . . . . . . . . . . .+0.05

PV (new pinion). . . . . . . . . . . . . . . . . . . . . . . . –0.13

Calculations

PT (original pack) . . . . . . . . . . . . . . . . . . . . . . . 0.90

PV (original drive pinion) . . . . . . . . . . . . . . . . –0.05

PT (master pack) . . . . . . . . . . . . . . . . . . . . . . . = 0.85

PV (new drive pinion).. . . . . . . . . . . . . . . . . . . –0.13

PT (new pack) . . . . . . . . . . . . . . . . . . . . . . . . . = 0.72

Example of Calculation “2”

Data:

PT (original pack) . . . . . . . . . . . . . . . . . . . . . . . 0.90

PV (original drive pinion) . . . . . . . . . . . . . . . . . –0.05

PV (new drive pinion).. . . . . . . . . . . . . . . . . . . . –0.13

Calculations

PT (original pack). . . . . . . . . . . . . . . . . . . . . . . . . 0.90

PV (original drive pinion) . . . . . . . . . . . . . . . . .+0.05

PT (master pack) . . . . . . . . . . . . . . . . . . . . . . . = 0.95

PV (new pinion). . . . . . . . . . . . . . . . . . . . . . . . –0.13

PT (new pack) . . . . . . . . . . . . . . . . . . . . . . . . . = 0.82

Determine Shim Packs Using a
Special Tool

In the following operations make sure that
all parts are clean, especially where indicated
below:

Between the contact surfaces of the special
tool components

The contact surfaces of the special tool
components

The contact surfaces of the carrier and the
drive pinion bearing case

Содержание RS-220

Страница 1: ...Two Speed Differentials RS 220 RS 230 RS 240 Maintenance Manual MM 0144 Issued 04 01 2 50...

Страница 2: ...arvinmeritor com To access information click on Products Services Tech Library Icon HVS Publications The screen will display an index of publications by type Additional Information Call ArvinMeritor...

Страница 3: ...y Parts After Cleaning 17 Prevent Corrosion on Cleaned Parts Inspection Storage 19 Section 4 Adhesives Adhesives 20 Features of Liquid Adhesives 22 Applying Liquid Adhesives Chemical Gasket Material 2...

Страница 4: ...View Exploded View 53 49 50 46 45 47 55 43 42 51 54 44 39 40 41 1 3 2 28 48 62 60 61 59 58 57 56 38 36 37 35 34 52 33 32 29 31 30 26 24 22 21 19 39 63 14 15 17 16 5 12 10 9 7 8 11 12 6 27 25 23 20 13...

Страница 5: ...ng Cup Pinion Inner 13 Fasteners Case Assembly 45 Bearing Cup Outer 14 Shaft for Differential Pinions 46 Bearing Cone Outer 15 Washer 47 Pinion Bearing Spacer 16 Planetary Gears 48 Bearing Cone Pinion...

Страница 6: ...e second ratio has a planetary system of straight teeth located under a hypoid ring gear First Gear Ratio High Speed At high speed the sun gear engages with the case half and blocks the operation of t...

Страница 7: ...ct the driveline universal joint from the pinion input yoke or flange on the carrier 3 Place jack stands under each spring seat of the axle to hold vehicle in the raised position 4 Remove the plug fro...

Страница 8: ...mer such as Chicago Pneumatic CP 4181 Puler or equivalent to loosen tapered dowels and axle shaft 2 Place the round hammer bit against the axle shaft flange between the hub studs Operate the air hamme...

Страница 9: ...ifferential until it is in the low speed position LS This operation tends to eliminate the interference between the sun gear and the mouth of the housing helping to make the disassembly of the differe...

Страница 10: ...9 LONG WITH ONE END SLOTTED TO FIT PLATE 4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE 5 WELD 6 SHAPE AND SIZE OF HOLES TO FIT CARRIER 7 23 1 2 CENTER TO CENTER OF PIPE 8 CHAMFER END OF PIPE FOR WELDI...

Страница 11: ...and a plastic mallet Figure 2 11 2 Remove the bolts from the top of the carrier 3 Simultaneously remove the selector and the sun gear Figure 2 12 If necessary rotate the sun gear to facilitate its rem...

Страница 12: ...Backlash in Section 8 Figure 2 15 8 Remove the cotter key from the right side adjustment nut Figure 2 16 9 Remove the capscrews and washers that hold the bearing caps on the carrier Figure 2 17 10 Man...

Страница 13: ...the ring gear from the plain half of the case to replace some of the parts if necessary WARNING Observe all warnings and cautions provided by the tool manufacturer to avoid serious personal injury and...

Страница 14: ...Separate the case halves Remove the internal components in the sequence specified in Figures 2 27 2 28 2 29 and 2 30 To disassemble the case use a press or a hammer and a brass bar making contact with...

Страница 15: ...move the shafts 14 Remove the side gears carefully without loosening and mixing the bearings 15 Remove the inner and outer washers Figure 2 33 16 Place the bearings and spacers in plastic bags Remove...

Страница 16: ...case Figure 2 36 4 Remove the pinion case fastening screws and washers Figure 2 37 CAUTION Do not insert wedges or chisels between the pinion and differential cases Damage to components can result 5...

Страница 17: ...e inner bearing cone and bearing spacer will remain on the pinion shaft 4 If a press is not available use a leather plastic or rubber mallet to drive the pinion through the bearing cage 5 Use a press...

Страница 18: ...flange area with metal or wood blocks 8 If you need to replace the pinion bearings remove the inner bearing cone from the drive pinion with a press or bearing puller The puller MUST fit under the inne...

Страница 19: ...ring puller Figure 2 46 12 If equipped with a two piece spigot bearing remove the inner race from the pinion using a bearing puller 13 Remove the outer race roller assembly from the carrier using a dr...

Страница 20: ...r polished parts in a hot solution tank or use strong alkaline solutions for cleaning or the smooth sealing surface may be damaged Rough Parts 1 Clean rough parts with the same method as cleaning grou...

Страница 21: ...l lubricant from the bearings knuckle hub and hubcap Inspect the cup the cone and the rollers and cage of all bearings If any of the following conditions exist you must replace the bearing 1 The cente...

Страница 22: ...washer seatings half rounds for installing the arms of the spiders on both halves of the satellite case 2 Side gear and pinion bearing surface 3 Diameters of the trunnion ends of the spider 4 Teeth a...

Страница 23: ...the splines and for out of roundness of the flange bores Case Check for cracks on any surface or burrs on the machined parts Yoke Replace the yoke if it shows excessive wear in the retainer area Carri...

Страница 24: ...alent 1 Clean the oil dirt and old adhesive from all threads and threaded holes Use a wire brush 2 Apply four or five drops of Meritor Liquid Adhesive Loctite 680 or equivalent inside each threaded ho...

Страница 25: ...water for 15 minutes Have your eyes checked by a doctor as soon as possible The following silicone gasket products or equivalent can be used for Meritor components O Three Bond Liquid Gasket No TB 121...

Страница 26: ...oles Carefully clean the dirt oil grease or moisture from the threaded holes and from the fastener threads This must be done with trichlorethylene or other chlorinated solvents Assemble Parts Before b...

Страница 27: ...asket material Applying Silicone Gasket Materials WARNING Take care when you use silicone gasket materials to avoid serious personal injury Follow the manufacturer s instructions to prevent irritation...

Страница 28: ...RNING Observe all warnings and cautions provided by the tool manufacturer to avoid serious personal injury and damage to components 5 Install a new rear bearing cone making sure that it is perfectly s...

Страница 29: ...against the spigot bearing 11 Release the pressure and lower the drive pinion and spigot bearing assembly 12 Install a new snap ring with appropriate snap ring pliers Figure 5 8 13 Lubricate the bear...

Страница 30: ...lues before you install the seal onto the drive pinion bearing cage Table A Models 220 224 230 Figure 5 10 Figure 5 11 PRESS Apply adhesive to this area Figure 5 12 New Bearings 1 7 4 0 N m 15 35 lb i...

Страница 31: ...ng cage several times and hook a dynamometer high quality scale to the end 4 Pull the cord with the dynamometer Read the value pounds or kilograms on the scale Refer to Table E Table E Code Thickness...

Страница 32: ...19 3 x 0 098 1 9 N m 16 55 x 0 113 1 9 N m Without a Press If a press is not available use the following procedure 1 Lubricate all the drive pinion bearings with the oil specified in Section 6 2 Insta...

Страница 33: ...Packs Using a Caliper 1 Write down the nominal mounting dimension ND for the drive pinion This dimension is the nominal distance taken from the center of the ring gear to the rear drive pinion bearin...

Страница 34: ...ing value will establish a master thickness for shim packs used for the assembly of a drive pinion whose ND dimension is equal to zero C Take note of the value obtained in Step B to use in the calcula...

Страница 35: ...stall the drive pinion bearing cage with the face that will be inserted in the carrier facing down on the rear drive pinion bearing Figure 5 20 5 Install the front bearing on the other face of the dri...

Страница 36: ...nch in the same cross sequence apply the following torque values 67 91 lb ft 90 125 N m Figure 5 25 11 Check if the differential case assembly bearing housing and the special tool centering disks are...

Страница 37: ...shim pack Place the pointer on the centering shaft Slide the pointer across the centering shaft until maximum value is indicated Figure 5 28 Write down the maximum value Mv indicated by the pointer of...

Страница 38: ...nominal dimension Csnd Number 6 engraved on the end of the drive pinion signifies that the variation in the height of the pinion in relation to the differential nominal dimension is 0 06 mm lower tha...

Страница 39: ...ng Preload in this section Assemble the Main Differential and Ring Gear Assembly 1 Apply Shell 71032 Alvania EP 2 or Texaco 995 Multifak EP 2 grease in the holes of the side gears Install the bearings...

Страница 40: ...the spider Figure 5 40 10 Position the tapered side gear long hub and thrust washer 11 Install the main differential case plain half without changing the original alignment 12 Install four fasteners i...

Страница 41: ...and install with care as to not allow any grease to fall into the differential case Assemble the Differential Case Halves WARNING Observe all warnings and cautions provided by the tool manufacturer to...

Страница 42: ...cap capscrews Tighten the fasteners according to the specifications in Section 7 2 Install the cones in the cups and mount the differential case assembly Figure 5 46 3 Install the left side adjusting...

Страница 43: ...ew Assemble the Gear Shift Command Mechanism WARNING Take care when you use Loctite to avoid serious personal injury Follow the manufacturer s instructions to prevent irritation to the eyes and skin 1...

Страница 44: ...ft fork Install the Differential Carrier into Axle Housing WARNING Take care when you use Loctite to avoid serious personal injury Follow the manufacturer s instructions to prevent irritation to the e...

Страница 45: ...ition of the shift mechanism actuator 13 Install the washers and fastening nuts of the shift mechanism and tighten them to the torque value specified in Section 7 14 Connect the drive shaft and align...

Страница 46: ...be covered with a good film of anticorrosive oil In this event the differential must be stored in a closed box until it is used to protect it from dust and other impurities Oil Change Periods New or...

Страница 47: ...caps fasteners 295 360 220 265 295 360 220 265 575 705 425 520 High Torque 6 Capscrews ring gear and differential case 205 250 150 185 205 250 150 185 205 250 150 185 High Torque 7 Nuts lock plate fa...

Страница 48: ...Preload 1 The preload is obtained by the correct positioning of the bearing adjusting rings Figure 8 4 Gradually tighten the X ring until the backlash of the ring gear drive pinion is eliminated Zero...

Страница 49: ...measurement Figure 8 6 4 Loosen same ring X three or four notches or holes Tighten ring Y gradually to expand the bearing caps between 0 006 to 0 013 inch 0 15 0 33 mm for new bearings or 0 003 to 0...

Страница 50: ...ase the backlash Loosen ring X and tighten ring Y in the same proportion to avoid altering the bearing preload Figure 8 10 Verification Process 1 Apply yellow iron oxide diluted in fine oil on some of...

Страница 51: ...the drive pinion is not at the proper depth the contact can show tooth height variation If so alter the position varying the thickness of the shim pack of the drive pinion bearing case Refer to Table...

Страница 52: ...ar to increase the backlash if necessary to the maximum permitted for the contact area to move towards the heel drawing closer in the manner indicated in Figure 8 14 Refer to Check Hypoid Gear Set Bac...

Страница 53: ...the publication was approved for printing and is subject to change without notice or liability ArvinMeritor Commercial Vehicle Systems reserves the right to revise the information presented or discon...

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