Range Gear O.H

sb52926_node14 Page 1 of 26
43175-5 Range gear, overhaul

Unit removed
Special tools: 9991187, 9992000, 9992621, 9992671, 9994078, 9996205, 9996222, 9996315, 9996479, 9996600,
9996603, 9996673, 9996674, 9996686, 9996737, 9996897, 9996900, 9996901, 9996904, 9996925, 9996927,
9998351, 9998570, 88800174, 9998597
Other special equipment: 9988185, 1159794, 1159796
Dismantling
1
Remove the lifting eye and adapter.
Special tools: 9996479, 9996925
Remove the flange nut and O-ring, use a counterhold.
Special tools: 9998570
http://10.2.5.143:8800/impact3/application/staticdb/lang/enGB/sb52926_node14.xhtm 9/21/2013
Pull off the flange with O-ring.
Special tools: 9992621, 9992622, 9996600, 9996603, 9998597
4
Remove the emergency steering servo pump, if fitted.
5
Remove the speedometer sensor and the power take-off lid.
Remove the lid on the range cylinder.
Remove the screw which holds the piston to the piston rod.
Remove the range cylinder.
Note: This can be difficult to remove.
Press the range gear out of the housing.
Note: Make sure that the piston rod moves freely and that the range gear does not fall onto the floor or the press
table and get damaged.
10
Remove the housing, selector fork and planet gear from the press.
11
Remove the seal ring from the housing.
12
Remove the toothed wheel for the speedometer.
13
Remove the bearing circlip.
Other special equipment: 9988185
14
Press the bearing out.
15
Remove spacer sleeve (A), engaging ring (B) and synchronising cone (C) for low range and the ring gear (D).
16
Remove the circlip (A) from the ring gear (B), engaging sleeve (C), synchronising cone (D) and spring ring (E).
17
Press in the spring ring and remove the high range engaging ring.
Note: The planet wheel holder and shaft are balanced at the factory after assembly, and for this reason they must
not be pressed apart.
Cleaning and checking
18
Clean and check all components.
19
Check the wear surfaces of engaging rings and synchronising rings. Rings with completely or partly worn grooves
and blued surfaces must be changed. Synchonising rings which are blued from the inside, all the way to the
outside, must be changed.
20
Put the components on a table, so that they partly overlap the edge of the table. Make sure that the synchronising
cone lies flat on the engaging ring, and measure from the underside of the engaging ring to the top of the
synchronising ring. Measure at several points.
Synchronising New Min. mm

components
etc.
Low grange 57,7±0,3 56,6
High range 32,7±0,3 31,6
21
Also check that the planet wheels move freely and that the planet wheel end float is between 0.5–1.3 mm. Also
check the surface of the gear teeth.
Note: If one gear wheel needs to be changed, all the gear wheels, shaft stubs, needle roller bearings and washers
must be changed.
Note: If all is OK, continue to point33.
Dismantling
22
Put the planet wheel holder in the press, press out the shaft stubs.
Special tools: 9992000, 9996205
23
Remove the gear wheels, washers and rollers. Check that there are no burrs in the shaft stub holes.
Note: If any component has to be changed, all components must be changed.
Assembly
24
Install needle roller bearings (A) and spacer washers (B) in the planet wheel holder (C), steel washers (D) and
metal washers (E).
25
When you install the needle roller bearings in the planet wheels, use a sleeve (A) of Ø 32,4 mm and length 40 mm.
This is to facilitate assembly.
26
Install the thrust washers and put the planet wheels in the planet wheel holder.
Note: The steel washers should be closest to the wheels.
27
The shaft stubs should fit easily into the holder and should lie flush with the planet wheel holder.
Note: Check that the shaft stubs do not deviate from the planet wheel holder plane during pressing.
28
Fix the press tool in a vice and install the tool.
Special tools: 9991187, 9996600, 9996603, 9996673, 9996674, 9996686, 9996897
29
Put the planet wheel holder in the press tool and upset the shaft. Press until 6.5 tonnes of press force is achieved.
30
Turn the rivetting punch so that the next press mark comes between the previous marks. Press until 6.5 tonnes of
press force is achieved.
31
Remove 9996897 and install 9996927, place the punch so that the shaft stub is marked in the cutouts in the planet
wheel holder. Press until 6.5 tonnes of press force is achieved.
Special tools: 9996897, 9996927
32
Check that the wheels roll easily and that the end float is between 0.6-1.3 mm.
Assembly
33
Oil all bearings, sliding surfaces and O-rings with gearbox oil during assembly.
34
Install the high range engaging ring circlip. Press the circlip together and install the engaging ring.
35
To ensure that the correct detent force is obtained in the synchronising components, spring ring (E) on the inside
of the engaging ring must be replaced by a new one.

Install the high range synchronising ring (C), annulus (B), engaging sleeve, circlip (A), low range synchronising
cone (D).
36
Press the bearing in until it bottoms.
37
Install the thickest possible bearing circlip.
38
Install the selector fork, spacer sleeve and piston rod.
Note: If the screws have been loose or have been removed, the top screw must be tightened first. Torque to 75±5
Nm. Screws must be rivetted with centre punch marks.
Specifications:
75±5 Nm
39
70mm
80mm
Put the components on the edge of a table. Lift the range housing carefully, install the tools. Press carefully and
check from beneath that the coupling ring has come into the housing correctly.
Note: If diameter of the range housing has 80mm to add tool (F) 9996924.
(A) 9996315
(B) 9992671
(C) 9996222
(D) 9996901
(E) 9996925
(F) 9996924
Special tools: 9996315, 9992671, 9996222, 9996901, 9996925, 9996924
40
Install the toothed wheel for the speedometer.
41
Fill the space between the seal lips with grease, part. no. 1161963.
Part number: 1161963
42
Put the seal ring on the drift and drive it in.

A=88800174
43
Press the flange on.
Special tools: 9992671, 9996222, 9996315, 9996901, 9996925
44
Install a new O-ring.
45
Note the cutouts in the flange, to lock the nut.

Install a new nut, and torque it to 400 +150 –50 Nm.
/
Use 9998570 as a counterhold on the flange.
Lock the nut with a centre punch mark through both cutouts in the flange.
Specifications:
400 +150 –50 Nm
/
46
Half fill the space between the piston rod seal lips with grease, part. no 1161963, also grease the cylinder.
47
Install the range cylinder.
Note: If necessary, replace O-ring (A) by a new one.
48
Clean the splitter gear cylinder and piston. Check that they are not damaged. Install new sealing rings on the
splitter gear cylinder. Install the new seals (1) and the support strap (2) on the piston.
Note: Before installing the sealing rings, lubricate the grooves in the piston with grease P/N 1161963.
49
Use a piston ring compressor, to avoid damage to the seals during assembly.
Use the longest screw as a guide when inserting the piston in the cylinder, to ensure that the piston rod O-ring
does not fall down into the cylinder.
Put the cleaned screw into the piston, screw it into the piston rod.
Note: Check that the countersink on the piston faces the piston rod.
Then slide the piston in towards the piston rod. Remove the screw which was used as a guide.
50
Install a new screw to hold the piston.
Torque to 40±5 Nm.
Specifications:
40±5 Nm
51
Fit the cover. Torque the screws alternately to 40±5 Nm.
Specifications:
40±5 Nm
52
Install the lid for the power take-off and speedometer sensor. Use a new gasket and O-ring if necessary.
Torque the screws to 40±5 Nm for the power take-off and 25±5 Nm for the speedometer.
Specifications:
screws= 40±5 Nm, speedometer= 25±5 Nm

Range Gear O.H

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Range Gear O.H

Hochgeladen von

Copyright:

Verfügbare Formate

sb52926_node14 Page 1 of 26

43175-5 Range gear, overhaul

Other special equipment: 9988185, 1159794, 1159796

Special tools: 9996479, 9996925

Remove the flange nut and O-ring, use a counterhold.

Special tools: 9998570

Pull off the flange with O-ring.

Special tools: 9992621, 9992622, 9996600, 9996603, 9998597

Remove the lid on the range cylinder.

Remove the range cylinder.

Note: This can be difficult to remove.

Press the range gear out of the housing.

Remove the seal ring from the housing.

Special tools: 9994078

Remove the toothed wheel for the speedometer.

Remove the bearing circlip.

Other special equipment: 9988185

Press the bearing out.

Special tools: 9996904

Cleaning and checking

Synchronising New Min. mm

Low grange 57,7±0,3 56,6

High range 32,7±0,3 31,6

check the surface of the gear teeth.

Note: If all is OK, continue to point33.

Special tools: 9992000, 9996205

Note: If any component has to be changed, all components must be changed.

Note: The steel washers should be closest to the wheels.

Fix the press tool in a vice and install the tool.

Special tools: 9991187, 9996600, 9996603, 9996673, 9996674, 9996686, 9996897

Special tools: 9996897, 9996927

of the engaging ring must be replaced by a new one.

Press the bearing in until it bottoms.

Special tools: 9996737

Install the selector fork, spacer sleeve and piston rod.

Other special equipment: 1159794

Special tools: 9996315, 9992671, 9996222, 9996901, 9996925, 9996924

Install the toothed wheel for the speedometer.

Part number: 1161963

Put the seal ring on the drift and drive it in.

Special tools: 88800174

Press the flange on.

Special tools: 9992671, 9996222, 9996315, 9996901, 9996925

Install a new O-ring.

Note the cutouts in the flange, to lock the nut.

Special tools: 9998570

Other special equipment: 1159794

Part number: 1161963

Install the range cylinder.

Note: If necessary, replace O-ring (A) by a new one.

Part number: 1161963

Special tools: 9998351

Other special equipment: 1159794

Other special equipment: 1159794

Other special equipment: 1159794

Das könnte Ihnen auch gefallen