Beruflich Dokumente
Kultur Dokumente
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1
FINAL DRIVE
SPECIAL TOOLS
PART NUMBER
TOOL DESCRIPTION
2872608
8700226
2.
3.
4.
5.
6.
Remove hub cap, cotter pin, front spindle nut, and washer.
Remove the spindle from the backside of the strut. Rotate
each bearing by hand and check for smooth rotation.
Visually inspect bearing for moisture, dirt, or corrosion.
Replace bearing if moisture, dirt, corrosion, or roughness
is evident. Inspect the spindle splines for wear.
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
ITEM
NUT TYPE
Aluminum Wheels
Lug Nut (1)
(Cast)
Steel Wheels
(Black / Camo)
SPECIFICATION
90 ft. lbs. (122 Nm)
#2
#1
Aluminum Wheel
Steel Wheel
(LE Models)
90 ft. lbs. (122 Nm)
(Standard Models)
35 ft. lbs. (47 Nm)
CAUTION
7.2
FINAL DRIVE
Hub Installation
1.
2.
7.
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
Out
Cone
Washer
5.
6.
Install spindle nut and hand tighten. Torque the spindle nut
after the wheel is installed.
Install wheel, wheel nuts, washers, and tighten evenly in a
cross pattern and torque to specification.
Refer to Torque Specifications on Page 7.2
7.3
FINAL DRIVE
Exploded View (2X4)
Disc Brake
Stud
Front Hub
Rim
Tire
18 ft. lbs. (24.9 Nm)
Use new bolts with
pre-applied
locking agent.
Wheel Nut
(Spec on page 7.2)
Washer
Spindle Shaft
Dust Cover
Slotted Nut
70 ft. lbs. (95 Nm)
7.4
Cotter Pin
FINAL DRIVE
FRONT HUB (4X4)
5.
Remove hub cap, cotter pin, front spindle nut, and washer.
6.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.
Rotate Bearing
7
3.
4.
2.
From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown in Step 3.
7.5
FINAL DRIVE
3.
Hub Installation
1.
2.
3.
4.
Bearing Installation
5.
6.
Out
Cone
Washer
5.
7.
8.
9.
7.6
FINAL DRIVE
10. Install brake caliper using new bolts. Tighten bolts to
specified torque.
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
18 ft. lbs.
(24 Nm)
Stud
Front Hub
Rim
Tire
Wheel Nut
(Spec on page 7.2)
Dust Cover
Washer
Slotted Nut
70 ft. lbs. (95 Nm)
Cotter Pin
7.7
FINAL DRIVE
DRIVE SHAFT / PROPSHAFT
Exploded View
RANGER 4X4 Front Driveshaft
30g Grease Packet
CV Joint
Plunging Joint
Inner Clamps
Circlip
Boots
Clamp
Clamp
Joint Kit
Shaft
Yoke
Front Yoke
O-ring
Spring Pin
7.8
FINAL DRIVE
DRIVESHAFT / CV JOINT
HANDLING TIPS
2.
3.
4.
boots.
5.
1.
6.
Remove hub.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
7.9
FINAL DRIVE
7.
8.
9.
Remove cotter pin and nut from lower A-arm ball joint.
Remove lower A-arm from ball joint.
2.
Remove cotter pin and castle nut from A-arm ball joint.
3.
4.
Slide strut off end of drive shaft and tie it up out of the way
of the shaft.
5.
7.10
FINAL DRIVE
6.
Remove the large end of the boot from the CV joint, slide
the boot back and separate the wheel spindle and CV joint
assembly from the axle shaft by pulling the shaft sharply
outward, away from the CV joint. It may be necessary to
tap the CV joint assembly outward with a soft faced
hammer.
Boot Capacity
30 Grams
Retaining Ring
Joint Capacity*
30 Grams
Joint Capacity**
20 Grams
Boot Capacity
20 Grams
7
*CV joint capacity: 30g if boot is replaced only.
Another 30g (60g total) if joint is cleaned.
**Plunging joint capacity: 20g if boot is replaced
only. Another 20g (40g total) if joint is cleaned.
Before installing the new boot, remove all grease from the
boot area and shaft.
Slide the new clamp and boot (small end first) over the
splined shaft, then slide (tap) the CV joint into the splines
of the axle. Install small boot clamp.
7.11
FINAL DRIVE
FRONT PROPSHAFT REMOVAL
Installation
1.
1.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.
3.
Install the lower A-arm onto the lower ball joint, torque nut
to 25 ft. lbs. (35 Nm) and install new cotter pin.
Cotter Pin
4.
25 ft. lbs.
(35 Nm)
2.
3.
Remove cotter pin and nut from lower A-arm ball joint.
Remove lower A-arm from ball joint. (See below)
4.
Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).
7.12
FINAL DRIVE
NOTE: Remove the drive shaft floor cover to help
align the roll pin removal tool to the roll pin for
removal. The drive shaft can be removed through
the floor covering.
2.
3.
CAUTION
4.
Force U-joint cross to one side and lift out of inner yoke.
7.13
FINAL DRIVE
Assembly
1.
2.
3.
4.
Install outer
disassembly.
yoke,
aligning
marks
made
before
5.
6.
7.
7.14
FINAL DRIVE
FRONT GEARCASE
CENTRALIZED HILLIARD
CAUTION
AWD Operation
Engaging Front Gearcase: The AWD switch may be turned on
or off while the vehicle is moving. Initially, the vehicles
electronic system will not enable the AWD until the engine RPM
is below 3100. Once enabled, the AWD remains while the front
gearcase is moving, it will not disengage until the rear wheels
regain traction.
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are
spinning , release the throttle before switching to AWD.
Rollers
CAUTION
Switching to AWD while the rear wheels are
spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.
Normal Operation: With the AWD switch off the vehicle
drives only the rear wheels (2 wheel drive). When the AWD
switch is activated it engages the Hilliard, locking both front
axles into All Wheel Drive.
Roller Cage
Roller Cage
& Bearings
Disengagement: As the front and rear wheels gain traction,
rotating very close to the same speed, the front wheels
overdrive the output hubs and the rollers are forced outward,
disengaging the AWD. The vehicle is now back to rear wheel
drive until the next loss of traction.
Output Hub
Armature
Plate
Coil
Cover
7.15
FINAL DRIVE
Centralized Hilliard Exploded View
3
17 ft. lbs.
(23 Nm)
15
5
6
14
11
10
6
15
17 ft. lbs.
(23 Nm)
20
12
13
14
24
26
16
25
18
23
17
19
22
14
10 ft. lbs.
(14 Nm)
21
8-30 ft. lbs.
(11-41 Nm)
REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
Set Screw
14
15
Screw
11
Thrust Button
16
Input Cover
Thrust Plate
17
18
19
Bushing
20
Gearcase LH
Dowel Pin
21
22
10
23
11
Rollers
14
24
Clutch Asm.
12
Bushing
25
13
Vent Fitting
26
Armature Plate
7.16
FINAL DRIVE
AWD Diagnosis
Possible
Wear Ring on
Armature Plate
OK Condition
3.
Coil
U-shaped insert
Armature Plate
7.17
FINAL DRIVE
5.
Inspect the rollers for nics and scratches. The rollers must
slide up and down and in and out freely within the roll cage
sliding surfaces.
8.
Rollers
Gearcase Removal
1.
2.
3.
CAUTION
Left
Side Panel
6.
7.
7.18
10. Remove the roll pin from the front drive shaft.Remove the
front drive shaft from the front gearcase splines.
11. Remove bolts securing bottom of gearcase to frame.
Remove vent line. Remove gearcase from right side of
frame.
Remove 4 Bolts
FINAL DRIVE
Gearcase Disassembly / Inspection
1.
2.
7.
Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B).
Inspect the ring gear (C) for consistent wear patterns. The
surfaces should be free of nicks and scratches.
3.
6.
8.
C
A
9.
Clean all parts and inspect spacers for wear. Inspect ring
gear for chipped, broken, or missing teeth.
7.19
FINAL DRIVE
10. Use a flat head screwdriver to remove the retaining ring
from the output cover.
13. Remove the output hub (G) from the cover. remove the
thrust bearing (F) from the output hub (G). Inspect the
thrust bearing (F) and the dowel (H).
Retaining Ring
G
F
11. Remove the spacer washer (D), armature plate (E), and
rubber O-ring from the output cover.
D
O-Ring
12. Inspect the armature plate (E) for a consistent wear pattern.
Uneven wear of the armature plate (E) indicates a warped
plate, which may cause intermittent operation.
NOTE: See "FRONT GEARCASE DIAGNOSIS"
earlier in this chapter for more details.
E
I
7.20
FINAL DRIVE
16. Remove the other output hub (K) from the main gearcase.
Inspect the inner bearing (L) for wear. If there is excessive
wear, replace bearing as needed.
19. Install new seals into the gearcase housing and use new Orings for the gearcase input and output covers.
17. Remove the input cover (M), bearing (N), and the pinion
gear (O). Inspect the pinion gear (O) for chipped, broken,
or missing teeth. Replace the input cover O-ring.
As mentioned in the disassembly section, replace all Orings, seals, and worn components.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To replace,
press new bearing on to shaft.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement side to side.
4.
Install pinion shaft, bearing, and input cover with new oring and torque bolts to 17 ft. lbs. (23 Nm).
7.21
FINAL DRIVE
5.
Install the output hub (A) into the gearcase housing. The
output hub should spin freely.
8.
Install the retaining ring (F) into the output cover. Be sure
the retaining ring is properly seated into the cover.
A
F
6.
Install the other output hub (B) and thrust bearing (C) into
the output cover. Apply a small amount of grease onto the
thrust bearing.
9.
Install the ring gear (G) onto the output hub on the output
cover.
G
7.
Install the armature plate (D) and spacer washer (E) into the
output cover.
Backlash Plate
NOTE: Be sure backlash plate is in place.
7.22
10. Install the rollers and roll cage into the ring gear. Insert the
rollers as the roll cage is installed.
FINAL DRIVE
11. Install the output cover assembly onto the main gearcase.
Lay the gearcase on the side with the output cover facing
up.
The backlash screw is loctited into place. Use a heat gun to
lightly heat up the loctite on the screw (A).
3.
Armature plate tabs
fit into roll cage slots
Using a hex wrench, turn the back-lash screw out 3-4 turns.
Re-apply red loctite onto the bottom screw threads.
4.
5.
7.23
FINAL DRIVE
6.
Gearcase Installation
1.
2.
4 Bolts
30 ft. lbs. (41 Nm)
7.24
FINAL DRIVE
REAR DRIVE
Exploded View
30 ft. lbs.
(41 Nm)
Rear Gearcase
Coil
A-arm bolts
Shaft
Bushings
Shock
Upper A-arm
Bushings
30 ft. lbs.
(41 Nm)
Caliper
18 ft. lbs.
(24 Nm)
A-arm bolts
Nuts
Bearing
Bushings
Lower A-arm
Carrier Bolt
Shaft
30 ft. lbs.
(41 Nm)
Shaft
Snap Ring
Bushings
Hub Removal
1.
1.
2.
3.
2.
3.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
7.25
FINAL DRIVE
4.
5.
7.
Remove the upper and lower control arm bolts from the rear
hub / bearing carrier.
8.
Remove hub cap, cotter pin, front spindle nut, and washer.
Hub Disassembly
1.
6.
From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown.
NOTE: Drive bearing out evenly by tapping on outer
race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.
7.26
FINAL DRIVE
3.
Hub Assembly
1.
Hub Installation
1.
2.
3.
2.
3.
CAUTION
Use an arbor and press only on the outer race,
as bearing damage may occur.
7.27
FINAL DRIVE
4.
2.
Remove upper carrier bolt. Slide the rear drive shaft out of
the bearing carrier by pulling the bearing carrier assembly
outward and tipping it down to remove the shaft.
3.
Pull the rear drive shaft straight out of the frame. Use short
sharp jerks to free the circlip from the gearcase. The circlip
holds the drive shaft in the gearcase.
4.
30 ft. lbs.
(41 Nm)
5.
6.
Install the washer with domed side out. Install the spindle
retainer nut.
7.
8.
7.28
FINAL DRIVE
CV Joint / Boot Replacement
1.
6.
Remove the large end of the boot from the CV joint and
slide the boot back.
7
NOTE: Photo above is shown without shaft for
clarity. Wipe grease away from recess in CV joint
inner hub to locate snap ring
3.
Open the snap ring using a snap ring pliers or small needle
nose pliers. Tap CV housing off shaft with a soft faced
hammer while holding snap ring open.
Spread ends of snap ring
to remove joint from shaft
7.
Before you assemble the CV joint, slide the new boot (small
end first) and clamp over the splined shaft.
7.29
FINAL DRIVE
8.
11. While pulling out on the CV shaft, fully extend the CV joint
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the axle.
Grease
PN 1350047
Boot Capacity
50 Grams
Boot
Small Clamp
Boot Capacity
50 Grams
Boot
Grease
PN 1350047
Large Clamp
Retaining
Ring
Joint Capacity*
50 Grams
Plunging Joint
Spring Ring
Figure 7-31
7.30
FINAL DRIVE
Installation
1.
4.
Lift bearing carrier into place and install the bolt into the
upper control arm. Torque bolt to 30 ft. lbs. (41 Nm).
Slide the rear drive axle into the bearing carrier hub.
30 ft. lbs.
(41 Nm)
2.
Install a new circlip onto the rear drive shaft. Apply AntiSeize Compound onto the rear driveshaft splines (both
ends).
5.
Apply Anti-Seize
New Circlip
3.
Flat washer
Out
Cone
Washer
Cone
washer
dome to
outside
7.31
FINAL DRIVE
REAR PROPSHAFT
4.
5.
Remove the shaft by placing the brake disc over the top of
the rear frame support and under the front frame support.
Removal
1.
Remove the pin clips from upper and lower cargo box
shock pins and remove shock. Carefully allow cargo box
to rest in the dump position as you remove the propshaft.
Rear Frame
Support
WARNING
Support the cargo box while the shock is removed
to prevent injury or damage.
2.
Front Frame
Support
Installation
3.
1.
2.
Slide the shaft onto the rear gearcase input shaft and then
slide it onto the transmission shaft.
Install a new roll pin into the propshaft
Install the parking brake caliper and torque mounting bolts
to 18 ft. lbs. (24 Nm).
Install cargo box shock, mounting pins and pin clips.
Remove the two bolts that secure the rear parking brake
caliper. Suspend the brake caliper assembly from the frame
with a piece of wire. (Refer to Chapter 9 for more
information on the rear parking brake)
3.
4.
5.
7.32
FINAL DRIVE
REAR GEARCASE (DIFFERENTIAL)
General Operation
The RANGER rear gearcase has three traction operational
modes: AWD, Differential Lock, and Differential Unlock.
Locking the rear differential is beneficial in low traction and
rough terrain conditions. Unlocking the rear differential makes
maneuvering easier and minimizes damage to turf and sensitive
terrains.
Shift Yoke
AWD
Shift yoke slides clutch gear to
lock and unlock the rear differential
Differential - Locked
Clutch Gear
Differential - Unlocked
Locked Mode
Clutch Gear
IRS Axle
Locked
Locked
Unlocked Mode
IRS Axle
Clutch Gear
Unlocked
7.33
FINAL DRIVE
Operation Modes
Differential Unlocked
Differential Locked
AWD Mode
7.34
FINAL DRIVE
Differential Removal
Differential Disassembly
1.
2.
3.
1.
2.
3.
Remove the bolts that secure the carrier cover (A) bolts to
the carrier housing (B).
4.
7.35
FINAL DRIVE
4.
6.
7.
5.
Inspect the tip of the solenoid (F) for wear. If the tip of the
solenoid is flat the solenoid may need to be replaced.
D
8.
Remove the clutch gear (G) from the carrier cover (B) and
shift yoke (H).
J
K
D
7.36
FINAL DRIVE
9.
Inspect the shift yoke (H), shift lever (J), and shift lever
return spring (K).
12. Thread the bolt into the shift yoke pivot shaft (L).
H
13. Carefully pull the shift yoke pivot shaft (L) out of the carrier
cover.
10. Remove the set screw.
L
11. Remove the shift yoke pivot shaft (L) Use a 1/4 in.- 20
coarse thread bolt approximately 3 in. long to thread into
the pivot shaft.
14. Remove the shift lever (M) and springs (N) from the shift
yoke (H). Inspect the components for wear and replace as
needed.
7.37
FINAL DRIVE
15. Remove the pinion shaft seal (P) using a seal puller.
2.
C
A
3.
4.
Install the spring lever and shift yoke into the carrier cover,
if previously removed.
Differential Assembly
1.
7.38
FINAL DRIVE
5.
Assemble the shift yoke (D), shift lever (G), spring lever
(F), and return spring (E).
8.
Install the new lightly greased O-ring (K) onto the carrier
cover.
H
Carrier Cover
F
E
D
K
6.
Use the bolt that was used to remove the shift yoke pivot
shaft (H) to reinsert the shaft into the carrier cover. Place
the shift yoke assembly into the carrier cover and secure
with the shift yoke pivot shaft (H).
Install Shift Yoke Assembly
9.
Install the carrier cover bolts. Tighten and torque the bolts
in a criss cross pattern to 25-35 ft.lbs. (34-48 Nm).
25-35 ft. lbs.
(34-48 Nm)
7
7.
10. Install the rear differential mount brackets from the rear
differential onto the rear differential. Torque the bracket to
differential bolts to 26-33 ft.lbs. (35-45 Nm)
7.39
FINAL DRIVE
Differential Installation
1.
Bracket to Frame
38-42 ft. lbs. (35-45 Nm)
2.
Slide the rear propshaft onto the rear differential input shaft.
3.
4.
Fill Plug
40 ft. lbs.
(54 Nm)
Drain Plug
30-45 in. lbs.
(3-5 Nm)
7.40
FINAL DRIVE
Differential Exploded View
8
10
ft. lbs.
11 40
(54 Nm)
20
5
4
3
1
12
6
13
12
19
14
17
38
21
18
15 16
37
22
23
36
24
31
35
3
4
25
34
29
33
REF#
DESCRIPTION
QTY
27
32
ft. lbs.
30 30-40
(41-52 Nm)
REF#
26
28
DESCRIPTION
QTY
20
Pinion Nut
21
22
Vent Tube
23
Pinion Spacer
AR
24
25
Clutch Gear
Drain Plug
26
Shift Yoke
27
O-Ring
28
Shift Lever
10
29
11
30
12
Gear-Side, Differential
31
Hex Bolt
13
32
14
33
Differential Cross-Pin
15
AR
34
Differential Roll-Pin
16
35
Pinion Spacer
AR
17
36
AR
18
37
19
Set Screw
38
7.41
FINAL DRIVE
NOTES
7.42