Contents: Removal ↧ Installation ↧
Removal
1. Raise the vehicle.
2. Remove the front wheels.
3. Remove the brake calipers.
4. If installed, remove the gearbox guard.
5. Mark the relative positions of the drive shaft and the pinion fork.
6. Loosen the bolts (6) and remove the covers (7) from the fork (1) of the front axle drive gear.
Warning: When removing the drive shaft, do not strike the joint or place a lever between the fork and the joint, otherwise the joint may be damaged.
7. Disconnect the propeller shaft (2) from the yoke (1). Wrap the bearing caps with insulating tape to prevent loss of the bearing rollers.
8. Hang the cardan shaft to the side with a wire.
9. Measure the turning torque of the drive gear of the gearbox.
Record the torque value to check the correct assembly. The turning torque gives the combined value of the preload in the following units:
- bearings of the drive gear.
- seal of the drive gear.
- gearbox housing bearings.
- axle shaft bearings.
- axle shaft seals.
10. Mark the relative positions of the cardan joint fork and the pinion shaft.
11. Attach the fork lock key to the fork to prevent it from turning.
12. Holding the fork with a wrench, unscrew the fork mounting nut.
13. Install the nut (2) and screw (3) of the fork puller into the key (1).
14. Holding the fork with a key, turn the puller screw to pull the fork off the drive gear shaft. Remove the deflector.
Warning: Remove the fork seal carefully, do not scratch the seal seat.
15. Using a suitable tool, remove the fork seal.
Warning: Remove the fork seal carefully, do not scratch the seal seat.
Installation
1. Using a mandrel, press the oil seal into the axle gearbox housing.
2. Apply sealant to the splines of the universal joint fork.
3. Install the deflector. Install the fork according to the relative position marks made before removal.
4. Using a soft-faced hammer, seat the fork on the gear shaft until several turns of the gear shaft thread emerge.
5. Install the washer and screw on the new fork mounting nut.
6. Attach the fork lock key to the fork to prevent it from turning.
7. Tighten the fork mounting nut until the pinion shaft axial clearance is almost eliminated. At the same time, rotate the pinion shaft to ensure proper bearing seating.
8. Measure the turning torque of the drive gear shaft. Tighten the nut in small portions until the initial torque is exceeded by 0.4-0.6 Nm.
Caution: If the pinion turning torque is exceeded, the pinion will have to be removed and the deformable spacer will have to be replaced.
9. Once the specified turning torque is reached, turn the pinion shaft a few revolutions. Check the turning torque value, adjust the torque value if necessary.
10. Connect the front propeller shaft to the fork.
11. Check and adjust the oil level in the gearbox crankcase.
12. Install the gearbox protection.
13. Install the brake calipers.
14. Install the wheels.
15. Lower the vehicle.