Differential plate angle tooth replace

Hello everyone,

поради damage до bevel gear от rear axle driveТрябваше да го направя. replace на bevel както и crown gear.
Аз... noticed на damage through на typical howling noise when changing loads. Running line approx. 160TKm, маслото беше changed regularly - Защо го направи damage occur Сега...?

Scuffing на bevel gear - Не. signs на scuffing на ring gear, но increased roughness от tooth flanks.




Така че аз имам delved deeper into на topic again както и would like до pass на some information на теб...

На axle drive на Daily е hypoid gear, както е usual with rear-wheel drive vehicles. This means that на axis от bevel gear shaft е lower than that от ring gear. (positive axis offset)
Advantages - smoother running, higher load capacity поради larger bevel gear, more teeth аз engaged в same time, lower position от cardan shaft е advantageous в cars.

Disadvantage - поради stronger sliding movement от teeth, there аз higher friction losses (efficiency), higher demands на material както и lubricant (> hypoid gear масло)

На toothing на IVECO е от Klingenberg type, т.е. tooth backs have a constant width.

Bevel както и ring gears аз always replaced като pair (they have a pairing number) и са only available За 4x4 from IVECO with ET 7170858, 

https://www.suonama.com.cn/products/differential-plate-angle-tooth-for-iveco-daily-4x4-4x2?_pos=1&_psq=9%2F40&_ss=e&_v=1.0&variant=31613152198769

Bevel & ring gear както и measuring dummy


В addition, ако го използвате cpl. & want да направя "right" :

- 2x tapered roller bearings bevel gear shaft 42471125 (старо 7162215) original from Timken: HM803110 - inner diameter: - 41,275 mm, outer diameter88 900 мм. Width: 30,163 mm
- 2x tapered roller bearing differential/ring gear shaft 1905216 (старо 7164410) Timken original: Y32014X - Inner diameter: 70 mm, outer diameter110 мм, тот. Width: 25 mm

- - на Simmerring на flange (12) - има IVECO Et Nr 40101693 (~50,-а-а) е from Corteco както и since на article Брой 12015770B - dimensions 90mmx60mmx13mm

- голямата гайка на flange - IVECO ET 7162213

- ако necessary, shims за bevel gear shaft (2 sets в increments на 0.025 mm)
- ако necessary, individual shims на ring gear (в increments на 0.05 mm)

Adjusting/screw ring за bearing preload от differential housing



и след special tools:

на dummy bevel gear shaft IVECO ET 99370309 (или опитайте instead на measuring)
Dial gauge with holders
Outside micrometer вместо measuring на adjusting discs
Puller (separating knife)
3/4" ядки 36mm
friction coefficient или Drag torque meter
counterholder вместо cardan flange - self-made
tool вместо locking на adjusting ring/screw ring - self-made
torque wrench (min.450Nm)
spotting paste


На torque на picture е твърде small with 350Nm, I used a larger едно - 3/4" 80cm до 750Nm.



Като comparison value, I have/wanted до measure на existing drag torque на стария axle drive before disassembling - Не, не, не. However, this Беше толкова... small (approx. 0.3Nm) that Беше irrelevant за новото setting. На backlash between на bevel gear и crown gear Сега и аз бях. large.



На process -

drain маслото до remove, unscrew на cardan shaft в flange, loosen , flange, which не е easy with на axle installed, since Това е... VERY tight (tightening torque 450Nm). Да го направя this, I blocked на flange with a tool както и operated на toggle от 3/4" socket with a jack.
Remove на cover from на axle housing както и unscrew Двете. bearing brackets. Unlock на bearing preload adjuster както и continue screwing towards на diff до relieve на bearings. Сега diff together with на ring gear should да бъде removed. Но... that didn't work because на inner ring от right bearing Беше твърде. tight върху seat. Затова трябваше да го направя. drive на bearing, which will да бъде replaced anyway, inwards (left) with a mandrel until there е enough play, сега аз could remove Cpl. take еш unit. Ти... should не смесват adjusting както и shim washers.
На bevel gear shaft Сега мога. also да бъде easily removed, together with на spacer sleeve и small shim. Lever еш Simmerring в flange както и drive Издишай! outer rings от tapered roller bearings with a mandrel. Аз... have a brass pick за да не го правя. damage anything. На inner bearing ring also Има shim и large shim.


When making на settings / measurements, various default values ​​must да бъде achieved

- - на axial installation position от bevel gear shaft (adjusting washer) > measurement > calculation
- - на correct preload от bevel gear shaft bearings (adjusting washer) > friction value 1, 2 - 2, 4 Nm
- - на correct preload от bearings от Diff housing (screw ring) > friction value 2 - 2. 8 Nm
- на axial installation position от diff housing / ring gear (adjusting washers)

resulting в backlash from ring gear до bevel gear (0.15 - 0.20 mm) и contact pattern > how/where на teeth touch.

Така че, ако ти follow на IVECO repair instructions, strength от large shim за axial alignment от bevel gear shaft е first determined with на help от dummy bevel gear shaft. Използвайте dummy because то bearing surfaces аз slightly undersized и bearing inner rings може да бъде removed както и installed за measurements without Всички problems.
This е quite tricky, because Ти have до zero на dial gauge до holder base и ти need a VERY flat surface вместо this. (exact procedure в guide)


built-in dummy


dial gauge на dummy


На current bearing preload (coefficient на friction) е determined от installing на dummy shaft както и tightening на flange ядки (450Nm) и ако necessary, by exchanging на small Shim adjusted до desired 1.2 Nm до 2.4 Nm.

Bevel gear shaft shims 

https://www.suonama.com.cn/products/driving-gear-shim-7165064-7165066-7166992-for-iveco-daily?_pos=1&_psq=shim&_ss=e&_v=1.0


Friction measurement



Сега diff може да бъде installed with нов ring gear, нов bearings и стар shims. На bearings аз preloaded with на screw ring according до guideline и backlash from на bevel gear до crown gear (0.15 mm до 0.20 mm) е determined with на dial gauge. Depending на deviation, diff with на ring gear е removed again както и installed with other shims както и measured again.


Ако е correct, total friction torque може да бъде measured. Here на guide gives a incorrect value от 20 Nm до 28 Nm. That Не може да бъде. since на bearings от bevel gear shaft should have Аз съм тук. those от diff Не, не, не. Ако сте на лечение с Viraferon want до measure на total friction torque на flange, ти have до take на ratio на 5.22 into account. Only на friction torque from на diff bearings Има effect divided от 5.22. Така че, за example, при мин. 1.2 Nm + (2 Nm: 5.22) = 1.6 Nm (или при макс. 2.4 Nm + (2.8 Nm): 5.22) = 2,9 Nm.

Ако backlash както и coefficient на friction match, ти should definitely check на contact pattern. That е, как teeth roll изключване each other. Да го направя this, teeth от ring gear аз coated with spotting paste. Then на crown wheel е braked strongly (напр. mounting lever between crown wheel както и housing) и bevel gear shaft е turned на flange. This results в imprints от bevel gear tooth flanks на ring gear tooth flanks. This should да бъде approximately в middle от teeth.





Ако contact pattern е correct- Ти си... done ;-) и може secure (caulk) adjusting ring на diff и flange - Лудост.

Ако не, installation position от ring gear или bevel gear shaft must да бъде corrected accordingly :-(