Differential plate angle tooth replace

Hello everyone,

datorită damage la bevel gear al rear axle drive, A trebuit sa replace • bevel şi crown gear.
Eu... noticed • damage through • typical howling noise when changing loads. Running line approx. 160TKm, ulei a fost changed regularly - De ce a făcut damage occur Acum...?

Scuffing privind bevel gear - Nu. signs din scuffing privind ring gear, dar increased roughness al tooth flanks.




Deci am delved deeper into • topic again şi would like la pass privind some information Pentru tine...

, axle drive privind Daily este o hypoid gear, ca este usual with rear-wheel drive vehicles. This means that • axis al bevel gear shaft este lower than that al ring gear. (positive axis offset)
Advantages - smoother running, higher load capacity datorită larger bevel gear, more teeth sunt engaged la same time, lower position al cardan shaft este advantageous în cars.

Disadvantage - din cauza stronger sliding movement al teeth, there sunt higher friction losses (efficiency), higher demands privind material şi lubricant (> hypoid gear ulei)

, toothing privind IVECO este de Klingenberg type, adică tooth backs have a constant width.

Bevel şi ring gears sunt always replaced ca o pair (they have a pairing number) și sunt only available pentru 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 şi measuring dummy


În addition, dacă îl utilizați cpl. & want "right" :

- 2x tapered roller bearings bevel gear shaft 42471125 (vechi 7162215) original from Timken: HM803110 - inner diameter: - 41 275 mm, outer diameter: 88,900 mm, tot. Width: 30,163 mm
- 2x tapered roller bearing differential/ring gear shaft 1905216 (vechi 7164410) Timken original: Y32014X - Inner diameter: 70 mm, outer diameter: 110 mm, tot. Width: 25 mm

- Simmerring privind flange (12) - are IVECO Et Nr. 40101693 (~50,-â ța) este from Corteco şi since • article Nr. 12015770B - dimensions 90mmx60mmx13mm

- marele nebun pe flange - IVECO ET 7162213

- dacă necessary, shims pentru bevel gear shaft (2 sets în increments din 0.025 mm)
- dacă necessary, individual shims privind ring gear (în increments din 0.05 mm)

Adjusting/screw ring pentru bearing preload al differential housing



şi pe special tools:

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


, torque privind picture este prea small with 350Nm, I used a larger 1 - 3/4" 80cm la 750Nm.



Ca o comparison value, I have/wanted la measure • existing drag torque din vechiul axle drive before disassembling - Da. However, this a fost aşa small (approx. 0.3Nm) that A fost. irrelevant pentru noul setting. , backlash between • bevel gear şi crown gear a fost prea acum large.



, process -

drain uleiul la remove, unscrew • cardan shaft la flange, loosen Piuliţa pe flange, which nu este easy with • axle installed, since Este VERY tight (tightening torque 450Nm). Să facem this, I blocked • flange with a tool şi operated • toggle din 3/4" socket with a jack.
Remove • cover from • axle housing şi unscrew cei doi bearing brackets. Unlock • bearing preload adjuster şi continue screwing towards • diff la relieve • bearings. Acum... diff together with • ring gear should - Nu. removed. Dar... that didn't work because • inner ring al right bearing a fost prea tight pe ea seat. Aşa că a trebuit să drive • bearing, which will - Nu. replaced anyway, inwards (left) with a mandrel until there a fost enough play, acum I could remove Cpl. take în afara unit. Tu should nu amesteca adjusting şi shim washers.
, bevel gear shaft Acum pot also - Nu. easily removed, together with • spacer sleeve şi small shim. Lever în afara Simmerring la flange şi drive în afară de cele două outer rings al tapered roller bearings with a mandrel. Eu... have a brass pick ca să nu damage anything. , inner bearing ring also are shim şi a large shim.


When making • settings / measurements, various default values ​​must - Nu. achieved

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

resulting în backlash from ring gear la bevel gear (0.15 - 0.20 mm) și contact pattern > how/where • teeth touch.

Deci, dacă tu follow • IVECO repair instructions, strength al large shim pentru axial alignment al bevel gear shaft este first determined with • help al dummy bevel gear shaft. Foloseşti dummy because a bearing surfaces sunt slightly undersized şi bearing inner rings poate fi removed şi installed pentru measurements without orice problems.
This este quite tricky, because Tu have la zero • dial gauge la holder base şi tu need a VERY flat surface pentru this. (exact procedure în guide)


built-in dummy


dial gauge privind dummy


, current bearing preload (coefficient din friction) is determined de installing • dummy shaft şi tightening • flange alune (450Nm) și, dacă necessary, de exchanging • small Shim adjusted la desired 1,2 Nm la 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



Acum... diff poate fi installed with nou ring gear, nou bearings şi bătrân shims. , bearings sunt preloaded with • screw ring according la guideline şi backlash from • bevel gear la crown gear (0.15 mm până la 0.20 mm) este determined with • dial gauge. Depending privind deviation, diff with • ring gear este removed again şi installed with other shims şi measured again.


Dacă este correct, total friction torque poate fi measured. Here • guide gives a incorrect value din 20 Nm până la 28 Nm. That Nu se poate. since • bearings al bevel gear shaft should have 1,2 Nm <> 2,4 Nm și those al diff 2 Nm <> 2.8 Nm. Dacă want la measure • total friction torque privind flange, tu have la take • ratio din 5.22 into account. Only • friction torque from • diff bearings are effect divided de 5.22. Deci, pentru example, la min. 1.2 Nm + (2 Nm: 5.22) = 1,6 Nm (sau la max. 2.4 Nm + (2,8 Nm: 5.22) = 2.9 Nm.

Dacă backlash şi coefficient din friction match, tu should definitely check • contact pattern. That este, cum teeth roll off each other. Să facem this, teeth al ring gear sunt coated with spotting paste. Then • crown wheel este braked strongly (de exemplu: mounting lever between crown wheel şi housing) și bevel gear shaft este turned privind flange. This results în imprints al bevel gear tooth flanks privind ring gear tooth flanks. This should - Nu. approximately în middle al teeth.





Dacă contact pattern este correct, Tu esti done ;-) și poate secure (caulk) adjusting ring privind diff şi flange Nebunule.

Dacă nu, installation position al ring gear sau bevel gear shaft must - Nu. corrected accordingly :-(