Usage:
Start By:
a. remove steering clutch hub couplings
b. remove pinion flanges
c. remove drive shaft
1. Remove the cover for the bevel gear compartment
2. Remove nuts (1) from the bolts that hold the bevel gear on the shaft.
3. Remove the bolts that hold the bearing cages (2) on the right and left sides of the bevel gear shaft. Install two 3/8 - 16 NC forcing screws in the bearing cages. Tighten the forcing screws evenly and remove bearing cages (2) and shims. Keep the shims with their respective bearing cages for installation.
4. Remove the bolts that hold the pinion bearing cage assembly to the bevel gear case.
5. Install two 3/8 " - 16 NC forcing screws in the pinion bearing cage assembly. Tighten the forcing screws evenly and remove pinion bearing cage assembly (3) and shims. Keep the shims with the pinion bearing cage for installation.
7. Move the bevel gear shaft away from the bevel gear.
8. Remove bevel gear (5) and bevel gear shaft (4).
9. Remove the bearing cups, O-ring seals and lip-type seals from the two bevel gear bearing cages.
10. Remove the bearing cones from the bevel gear shaft with tooling (A).
Typical Example
11. Remove bolts (7) that hold the retainer in the pinion shaft (6).
NOTE: Keep the shims with the retainer for correct installation.
Typical Example
12. Remove pinion bearing cage (8) from the pinion with tooling (A).
NOTE: Keep the puller attachment away from the inner bearing cone when tooling (A) is installed.
Typical Example
13. Remove the O-ring seal and lip-type seal from pinion bearing cage (8).
14. Remove the bearing cups from pinion bearing cage (8).
15. Remove inner bearing cone (9) from pinion shaft (10) with tooling (A).
Install Bevel Gear & Pinion
1. Lower the temperature of bearing cups (11). Install bearing cups (11) in the pinion bearing cage.
2. Lower the temperature of bearing cups (12). Install bearing cups (12) in bevel bearing cages (2).
3. Heat bearing cone (9) to a maximum temperature of 135° C (275° F). Install bearing cone (9) on the pinion shaft. Install the pinion shaft in pinion bearing cage (8). Install bearing cone (13) on the pinion shaft. Install O-ring seal (14). Install the lip-type seal in the pinion bearing cage with the lip of the seal toward the oil that is to be sealed.
4. Install the flange, retainer and bolts. Tighten the bolts which will pull the bearing cone on to the pinion shaft. Turn the pinion shaft while the bolts are tightened until a small preload is felt.
5. Install tooling (B) as shown and check the end play in the pinion shaft. Add enough shims behind the retainer to get 0 to 0.05 mm (0 to .002 in) end play in the pinion shaft. Install the O-ring, retainer, and lock and bolts.
6. Heat bearing cones (15) to a maximum temperature of 135° C (275° F). Install bearing cones (15) on the bevel gear shaft.
7. Put the bevel gear into position in the bevel gear case.
8. Install the bevel gear shaft through the bevel gear.
9. Install the O-ring seal and lip-type seal (17) in the left bearing cage. The spring loaded lip of the lip-type seal must be toward the bevel gear.
10. Install the left bearing cage with original amount of shims (16) behind the bearing cage.
11. Put bevel gear shaft (4) in position in bevel gear (5). Install the bolts and nuts that hold the bevel gear to the bevel gear shaft.
12. Install the O-ring seal and lip-type seal (19) in the right bearing cage. The spring loaded lip of the lip-type seal must be toward the bevel gear.
13. Install two 1/2 " - 13 NC guide bolts (18). Install the right bearing cage on the shaft without shims. Install the bolts and tighten the bolts evenly, while the bevel gear shaft is turned, until a small amount of bearing preload is felt.
14. Tighten nuts (1) on the bevel gear to a torque of a torque of 240 ± 40 N·m (178 ± 30 lb ft).
15. Install tooling (B) on the end of the bevel gear shaft. Loosen the bolts around the right bearing cage evenly until there is no end play or preload on the bevel gear shaft.
16. Make a measurement of the clearance between the right bearing cage and the bevel gear case with a feeler gauge. The clearance must be the same at all bolt locations.
17. Remove tooling (B) and the right bearing cage. Install shims equal to the thickness measured minus 0.18 mm (.007 in). Install the right bearing cage.
18. Check the amount of torque needed to turn the bevel gear shaft constantly for two to three turns. The torque must be 3.9 to 5.6 N·m (35 to 50 lb in). Add or remove shims as necessary if the torque is not correct.
19. Slide pinion bearing cage assembly (3), with the large oil hole in the bearing cage up, into the bevel gear case.
20. Install original shims (20) behind the pinion bearing cage. If the original shims are not available, install enough shims behind the pinion bearing cage to get the heel of the bevel gear in alignment with the pinion gear.
21. Install tooling (B) to check the gear clearance (backlash) between the bevel gear and pinion. Turn the gears and check the gear clearance (backlash) at several places to find out the place where there is the least amount of gear clearance (backlash). The correct gear clearance (backlash) for a power shift machine is 0.20 + 0.10 or - .08 mm (.008 + .004 or - .003 in). The correct gear clearance (backlash) for a direct drive machine is 0.25 + 0.10 or - .08 mm (.010 + .004 or - .003 in).
22. The gear clearance (backlash) can be increased, or decreased by removal of shims from one bearing cage and installation behind the other.
23. Preload on the bearings of the bevel gear shaft will not be changed if shims are moved from one side to the other and the thickness of the shims is kept the same.
24. After the gear clearance (backlash) and bearing preload adjustments have been made, check the tooth contact between the bevel gear and pinion as follows:
a. Put a Prussian blue, red lead or paint with a brush on the bevel gear teeth. Turn the pinion nand check the contact area of the teeth on the drive side of the bevel gear. When the tooth contact on the drive side is correct, reverse side must also be correct.
Correct Tooth Contact Setting
b. With no load, the correct tooth setting will be as shown. The area of contact starts near the toe of the gear and goes about 30% up the length of the tooth with this setting. When a load is put on the gear, it will be over the correct area of the teeth.
Short Toe Contact Setting
c. If the bevel pinion shaft is too far away from the bevel gear, short toe contact will be the result as shown. The teeth of the pinion will be in contact with toe end of convex faces (part that makes a curve toward the outside) and top edge of heel end of concave faces (part that makes a curve toward inside). To correct this, move the pinion shaft closer to the bevel gear. To do this, remove shims between the pinion bearing cage and bevel gear case. Check gear clearance (backlash) and tooth contact again.
Short Heel Contact Setting
d. If the pinion shaft is too near to the center of the bevel gear, short heel contact will be the result as shown. The teeth of the pinion shaft will be in contact with the toe ends of concave faces (part that makes a curve toward the inside) and the heel end of convex faces (part that makes a curve toward the outside). To correct this, move the pinion shaft away from the bevel gear. To do this, add shims between the pinion bearing cage and bevel gear case. Check gear clearance (backlash) and tooth contact again.
NOTE: Several adjustments must be made for the correct tooth contact setting. If the gear clearance (backlash) is changed, the tooth contact setting will change.
e. Remove all of the Prussian blue, red lead or paint from the bevel gear and pinion.
End By:
a. install drive shaft
b. install pinion flanges
c. install steering clutch hub couplings