Differential plate angle tooth replace

Hello everyone,

V dôsledku damage k bevel gear na tému rear axle drive, Musel som replace a bevel a crown gear.
I noticed a damage through a typical howling noise when changing loads. Running line approx. 160TKm, olej bol changed regularly - prečo damage occur Teraz...?

Scuffing na tému bevel gear - nie signs z scuffing na tému ring gear, ale increased roughness na tému tooth flanks.




Takže som delved deeper into a topic again a would like do pass o some information pre teba...

ie axle drive na tému Daily rá hypoid gear, rovnako ako usual with rear-wheel drive vehicles. This means that a axis na tému bevel gear shaft ci lower than that na tému ring gear. (positive axis offset)
Advantages - smoother running, higher load capacity v dôsledku larger bevel gear, more teeth ác engaged na same time, lower position na tému cardan shaft ci advantageous on cars.

Disadvantage - kvôli stronger sliding movement na tému teeth, there ác higher friction losses (efficiency), higher demands o material a lubricant (> hypoid gear olej)

ie toothing na tému IVECO je Klingenberg type, tj tooth backs have a constant width.

Bevel a ring gears ác always replaced ako a pair (they have a pairing number) a sú only available pre 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 a measuring dummy


V additionAk to použijete, tak to stlačte. & want robiť "right" :

- 2x tapered roller bearings bevel gear shaft 42471125 (starý 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 (starý 7164410) Timken original: Y32014X - Inner diameter: 70 mm, outer diameter: 110 mm, tot. Width: 25 mm

- Simmerring na tému flange (12) - má IVECO Et Nr. 40101693 (~50,-âââ) je from Corteco a since a article č. 12015770B - dimensions 90mmx60mmx13mm

- veľký orech na flange - IVECO ET 7162213

- ak necessary, shims pre bevel gear shaft (2 sets on increments z 0.025 mm)
- ak necessary, individual shims na tému ring gear (v increments z 0.05 mm)

Adjusting/screw ring pre bearing preload na tému differential housing



a na tému special tools:

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


ie torque na tému picture je príliš small with 350Nm, I used a larger 1 - 3/4" 80cm do 750Nm.



Ako comparison value, I have/wanted do measure a existing drag torque starých axle drive before disassembling To. However, this bolo to tak small (approx. 0.3Nm) that bolo irrelevant pre nové setting. ie backlash between a bevel gear a crown gear bol teraz príliš large.



ie process -

drain olej až remove, unscrew a cardan shaft na flange, loosen orech na flange, which nie je easy with a axle installed, since je VERY tight (tightening torque 450Nm). Urobiť this, I blocked a flange with a tool a operated a toggle 3/4" socket with a jack.
Remove a cover from a axle housing a unscrew dve bearing brackets. Unlock a bearing preload adjuster a continue screwing towards a diff do relieve a bearings. Teraz diff together with a ring gear should be removed. Ale that didn't work because a inner ring na tému right bearing bol príliš tight k téme seat. Tak som musel drive a bearing, which will be replaced anyway, inwards (left) with a mandrel until there bol enough play, teraz som could remove KP. take von unit. Ty should a nemiešať adjusting a shim washers.
ie bevel gear shaft Teraz už môžeme. also be easily removed, together with a spacer sleeve a small shim. Lever von Simmerring na flange a drive von z oboch outer rings na tému tapered roller bearings with a mandrel. I have a brass pick aby damage anything. ie inner bearing ring also má shim a large shim.


When making a settings / measurements, various default values ​​must be achieved

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

resulting v backlash from ring gear do bevel gear (0.15 - 0.20 mm) a contact pattern > how/where a teeth touch.

Takže ak follow a IVECO repair instructions, strength na tému large shim pre axial alignment na tému bevel gear shaft ci first determined with a help na tému dummy bevel gear shaft. Použi dummy because - bearing surfaces ác slightly undersized a bearing inner rings môže byť removed a installed pre measurements without žiadna problems.
This ci quite tricky, because Vy have do zero a dial gauge k holder base a ty need a VERY flat surface namiesto this. (exact procedure v guide)


built-in dummy


dial gauge na tému dummy


ie current bearing preload (coefficient z friction) je determined podľa installing a dummy shaft a tightening a flange matica (450Nm) a ak necessary, podľa exchanging a small Shim adjusted k desired 1.2 Nm až 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



Teraz diff môže byť installed with nové ring gear, nový bearings a staré shims. ie bearings ác preloaded with a screw ring according k guideline a backlash from a bevel gear k crown gear (0.15 mm až 0.20 mm) je determined with a dial gauge. Depending na tému deviation, diff with a ring gear ci removed again a installed with other shims a measured again.


Ak je correct, total friction torque môže byť measured. Here a guide gives a incorrect value z 20 Nm až 28 Nm. That To nemôže byť pravda. since a bearings na tému bevel gear shaft should have 1,2 Nm <> 2,4 Nm a those na tému diff 2 Nm < > 2,8 Nm. Ak want do measure a total friction torque na tému flange, vy have do take a ratio z 5.22 into account. Only a friction torque from a diff bearings má effect divided podľa 5.22. Takže, example, pri min. 1,2 Nm + (2 Nm: 5.22) = 1,6 Nm (alebo pri max. 2,4 Nm + (2,8 Nm: 5.22) = 2,9 Nm.

Ak backlash a coefficient z friction match, vy should definitely check a contact pattern. That je, ako teeth roll vypnuté each other. Urobiť this, teeth na tému ring gear ác coated with spotting paste. Then a crown wheel ci braked strongly (napr. mounting lever between crown wheel a housing) a bevel gear shaft ci turned na tému flange. This results v imprints na tému bevel gear tooth flanks na tému ring gear tooth flanks. This should be approximately v middle na tému teeth.





Ak contact pattern ci correct, you're done ;-) a môže secure (caulk) adjusting ring na tému diff a flange cvok.

Ak nie, installation position na tému ring gear alebo bevel gear shaft must be corrected accordingly :-(