Volvo Penta Aquamatic 250A, Руководство по ремонту

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Dismantling the universal joint
1. Remove the snap rings (80) which hold the needle
bearings in the yokes.
2. Use a hammer and drift to drive out the needle
bearings, see Fig. 9. Remove the spider.
Inspecting the universal joint
Examine the spider and needle bearings for looseness
and scoring in the bearing races. If there are any
faults, the spider should be replaced completely with
the needle bearings.
Also make sure that the needle bearing cages are
not loose in the yokes. If there is looseness, fit new
yokes.
3. Place the upper gear together with its shims in the
gear housing. Fit the needle bearings (28) with the
spacer ring (29) between the bearings and the lower
shaft circlips (35 and 36).
4. Tighten the nut (37) on the top of the countershaft
to a tightening torque of 59 Nm (45 lb.ft.).
NOTE: The nut has a left-hand thread. Use tool
884264 as a counterhold. In order to obtain the correct
axial clearance on the shaft (30), a choice can be
made between three nuts (37) with flats of different
thicknesses. Begin by fitting the nut with part No.
897311. Then measure the clearance between the nut
(37) and the bearing (9). The axial clearance should
be between 0.1–0.50 mm (0.004–0.020"). If the clear-
ance is greater up to 0.75 mm (0.030"), fit the nut with
part No. 814360. Where the clearance exceeds 0.75
mm (0.030") up to 1.05 mm (0.041"), fit the nut with
part No. 814361. If the clearance is greater than 1.05
mm (0.041"), the bearings (9) must be defective.
5. Measure the shoulder on the double bearing box by
using a micrometer, see measurement “A”, Fig. 5.
NOTE: The previously measured thickness of shims
(16) between the bearing box and the gear housing
should be included here.
6. Then measure up the corresponding recess in the
clamp ring (5). Use a depth gauge micrometer when
measuring.
7. Fit so many shims between the clamp ring and the
bearing box that the measurement “A” together with
the shims (16) exceeds the depth measurement in the
clamp ring by 0.03–0.05 mm (0.0012–0.0020").
8. Example: The measurement “A” is found to be 9.83
mm (0.387") and the shoulder in the clamp is 10.08
mm (0.397"). The difference is 10.08–9.83 = 0.25 mm
(0.397–0.387 = 0.010"). To this is then added 0.03–
0.05 mm (0.0012–0.0020").
In this case the shim thickness will be 0.25 + 0.05 =
0.30 mm (0.010 + 0.0020 = 0.0120"). With this thick-
ness of shims, the clearance between the clamp ring
and the gear housing will be the smallest possible but
the pressure on the double bearing box will be suffi-
ciently large.
9. Remove tool 884483 from the double bearing box.
Remove the spacer washer (17) and the shims, and fit
the seal ring (19) with tool 884312 so that the seal ring
does not lie against the bearing. Fit the circlip (27)
and spacer washer with shims.
10. Fit the O-ring (18) on the spacer washer (17)
using grease.
11. Fit the shims and the two O-rings (15) on the dou-
ble bearing box.
12. Place the clamp ring (5) and the double bearing
box on the universal joint. Fit the screw (24) and the
washer (23). Use VP thread sealant 1161053-2 on the
screws. Tighten the screw to a torque of 122 Nm (90
lb.ft.).
Assembling the universal joint
1. Fit new seal washers on the spider trunnions. Fit
the spider in the flange yoke.
2. Push the spider so far in one direction that the
needle bearing can be slid into the trunnion. Then
press in the needle bearing so far that the snap ring
can be fitted.
3. Fit the other needle bearing and snap ring in the
same way.
C. Fitting
Before fitting, clean the marking colour from all the
gears and lubricate all bearings and bolts
1. Fit the “lower” gear together with the measured
shims.
2. Fit the snap ring (32), the washer (34), the spring
(33) and the engaging sleeve (31) on the shaft (30).
Place the shaft in the lower gear.
Fig. 9