Adjusting the Drive Shaft
Adjusting the drive shaft
Adjusting the drive shaft
Preliminary work
1. Remove transmission.
2. Use engine support 9589 to secure the transmission on the assembly support.
3. Drain transmission oil.
4. Disassemble transmission.
5. Disassemble drive shaft as much as you need.
General information
Information
All components to be measured must be cleaned carefully before starting adjustment work. The components must be free of dust and grease. Dry all components thoroughly before taking measurements.
Information
The radial play of the loose gear wheels for all gears must be between 15 and 25 micron. 20 micron is always accepted as the target value for adjustment work.
Information
The synchronizer rings on the gear wheels to be measured must be removed before taking measurements.
Taking measurements with the synchronizer rings fitted can give an incorrect result.
Information
Use the smallest needle-roller bearing available for taking the first measurement for each loose gear wheel and then turn the loose gear wheel a number of times.
Measurement setup
Measurement setup
A - Compressed air switch
B - Pressure gauge
C - Measuring tower
D - Measuring plate
E - Support rod
F - Retainer plate
G - Lifting cylinder with measuring ram
H - Precision gauge
I - Measuring base
Adjusting radial play for 4th gear
Measurement setup for 4th gear
1. Set the compressed air switch on the measuring device P 9746 to 0, then connect the measuring device P 9746 to the compressed air supply and set the pressure to 1 bar.
2. Clamp drive shaft in measuring device P 9746.
3. Position measuring tower and measuring plate with respect to loose gear wheel for 4th gear and fix in place.
4. Position support rod on shift sleeve for 4th/3rd gear and fix in place so that the measuring plate is slightly pre-tensioned.
5. Position retainer plate under measuring plate and fix in place at this position.
6. Position lifting cylinder under loose gear wheel for 4th gear.
7. Insert precision gauge with measuring base into measuring plate, fit upper measuring base on loose gear wheel toothing and fix precision gauge in place.
8. Set precision gauge to 0.
9. Set pressure switch to 1. This applies pressure to the lifting cylinder and presses the measuring ram up.
10. Read off play on precision gauge and write it down.
11. Set pressure switch to 0. This relieves the pressure in the lifting cylinder and pushes the measuring ram down.
This measurement must be performed three times. You can then calculate the mean measured value.
Example:
Measurement result 1: 32 microns
Measurement result 2: 30 microns
Measurement result 3: 28 microns
Mean value from measurements 1 to 3: (32 microns + 30 microns + 28 microns) / 3 = 30 microns
12. Lift up the measuring plate, turn the loose gear wheel for 4th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 4: 30 microns
Measurement result 5: 29 microns
Measurement result 6: 28 microns
Mean value from measurements 4 to 6: (30 microns + 29 microns + 28 microns) / 3 = 29 microns
13. Lift up the measuring plate, turn the loose gear wheel for 4th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 7: 30 microns
Measurement result 8: 31 microns
Measurement result 9: 32 microns
Mean value from measurements 7 to 9: (30 microns + 31 microns + 32 microns) / 3 = 31 microns
14. Calculate the mean value for radial play on the loose gear wheel.
Example:
Mean value from measurements 1 to 3: 30 microns
Mean value from measurements 4 to 6: 29 microns
Mean value from measurements 7 to 9: 31 microns
Mean value of all measurements: (30 microns + 29 microns + 31 microns) / 3 = 30 microns
The roller bodies of the needle-roller bearings for the loose gear wheel for 4th gear are available in various thicknesses. The roller body thickness increases in increments of 4 microns.
15. Work out which new needle-roller bearing to use for the loose gear wheel for 4th gear if the average radial play is not between 15 microns and 25 microns.
Example:
Actual size of the fitted roller body (the smallest needle-roller bearing available was fitted before taking measurements in accordance with instructions): 2.500 mm
Average measured bearing clearance: 30 microns
Required bearing clearance: 20 microns
Difference between actual and required bearing clearance: 30 microns - 20 microns = 10 microns
Since there are always two roller bodies for bearing clearance, the difference must be divided by 2.
Required size of fitted roller body: 10 microns / 2 microns = 5 microns. This gives a required size of 4 microns - given the specified increments for roller body thickness.
The needle-roller bearing to be fitted must have a roller body diameter of 2.504 mm.
16. Fit new needle-roller bearing and repeat the measurements. If the radial play is not between 15 microns and 25 microns, the needle-roller bearing must be replaced in accordance with the new measurement result.
Adjusting radial play for 3rd gear
Measurement setup for 3rd gear
1. Set the compressed air switch on the measuring device P 9746 to 0, then connect the measuring device P 9746 to the compressed air supply and set the pressure to 1 bar.
2. Clamp drive shaft in the measuring device P 9746.
3. Position measuring tower and measuring plate with respect to loose gear wheel for 3rd gear and fix in place.
4. Position support rod on toothing base for 6th gear and fix in place so that the measuring plate is slightly pre-tensioned.
5. Position retainer plate under measuring plate and fix in place at this position.
6. Position lifting cylinder under loose gear wheel for 3rd gear.
7. Insert precision gauge with measuring base into measuring plate, fit upper measuring base on loose gear wheel toothing and fix precision gauge in place.
8. Set precision gauge to 0.
9. Set pressure switch to 1. This applies pressure to the lifting cylinder and presses the measuring ram up.
10. Read off play on precision gauge and write it down.
11. Set pressure switch to 0. This relieves the pressure in the lifting cylinder and pushes the measuring ram down.
This measurement must be performed three times. You can then calculate the mean measured value.
Example:
Measurement result 1: 32 microns
Measurement result 2: 30 microns
Measurement result 3: 28 microns
Mean value from measurements 1 to 3: (32 microns + 30 microns + 28 microns) / 3 = 30 microns
12. Lift up the measuring plate, turn the loose gear wheel for 3rd gear a further 120° and take another three measurements at this position.
Example:
Measurement result 4: 30 microns
Measurement result 5: 29 microns
Measurement result 6: 28 microns
Mean value from measurements 4 to 6: (30 microns + 29 microns + 28 microns) / 3 = 29 microns
13. Lift up the measuring plate, turn the loose gear wheel for 3rd gear a further 120° and take another three measurements at this position.
Example:
Measurement result 7: 30 microns
Measurement result 8: 31 microns
Measurement result 9: 32 microns
Mean value from measurements 7 to 9: (30 microns + 31 microns + 32 microns) / 3 = 31 microns
14. Calculate the mean value for radial play on the loose gear wheel.
Example:
Mean value from measurements 1 to 3: 30 microns
Mean value from measurements 4 to 6: 29 microns
Mean value from measurements 7 to 9: 31 microns
Mean value of all measurements: (30 microns + 29 microns + 31 microns) / 3 = 30 microns
The roller bodies of the needle-roller bearings for the loose gear wheel for 3rd gear are available in various thicknesses. The roller body thickness increases in increments of 4 microns.
15. Work out which new needle-roller bearing to use for the loose gear wheel for 3rd gear if the average radial play is not between 15 microns and 25 microns.
Example:
Actual size of the fitted roller body (the smallest needle-roller bearing available was fitted before taking measurements in accordance with instructions): 2.500 mm
Average measured bearing clearance: 30 microns
Required bearing clearance: 20 microns
Difference between actual and required bearing clearance: 30 microns - 20 microns = 10 microns
Since there are always two roller bodies for bearing clearance, the difference must be divided by 2.
Required size of fitted roller body: 10 microns / 2 microns = 5 microns. This gives a required size of 4 microns - given the specified increments for roller body thickness.
The needle-roller bearing to be fitted must have a roller body diameter of 2.504 mm.
16. Fit new needle-roller bearing and repeat the measurements. If the radial play is not between 15 microns and 25 microns, the needle-roller bearing must be replaced in accordance with the new measurement result.
Adjusting radial play for 6th gear
Measurement setup for 6th gear
1. Set the compressed air switch on the measuring device P 9746 to 0, then connect the measuring device P 9746 to the compressed air supply and set the pressure to 1 bar.
2. Clamp drive shaft in the measuring device P 9746.
3. Position measuring tower and measuring plate with respect to loose gear wheel for 6th gear and fix in place.
4. Position support rod on shift sleeve for 5th/6th gear and fix in place so that the measuring plate is slightly pre-tensioned.
5. Position retainer plate under measuring plate and fix in place at this position.
6. Position lifting cylinder under loose gear wheel for 6th gear.
7. Insert precision gauge with measuring base into measuring plate, fit upper measuring base on loose gear wheel toothing and fix precision gauge in place.
8. Set precision gauge to 0.
9. Set pressure switch to 1. This applies pressure to the lifting cylinder and presses the measuring ram up.
10. Read off play on precision gauge and write it down.
11. Set pressure switch to 0. This relieves the pressure in the lifting cylinder and pushes the measuring ram down.
This measurement must be performed three times. You can then calculate the mean measured value.
Example:
Measurement result 1: 32 microns
Measurement result 2: 30 microns
Measurement result 3: 28 microns
Mean value from measurements 1 to 3: (32 microns + 30 microns + 28 microns) / 3 = 30 microns
12. Lift up the measuring plate, turn the loose gear wheel for 6th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 4: 30 microns
Measurement result 5: 29 microns
Measurement result 6: 28 microns
Mean value from measurements 4 to 6: (30 microns + 29 microns + 28 microns) / 3 = 29 microns
13. Lift up the measuring plate, turn the loose gear wheel for 6th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 7: 30 microns
Measurement result 8: 31 microns
Measurement result 9: 32 microns
Mean value from measurements 7 to 9: (30 microns + 31 microns + 32 microns) / 3 = 31 microns
14. Calculate the mean value for radial play on the loose gear wheel.
Example:
Mean value from measurements 1 to 3: 30 microns
Mean value from measurements 4 to 6: 29 microns
Mean value from measurements 7 to 9: 31 microns
Mean value of all measurements: (30 microns + 29 microns + 31 microns) / 3 = 30 microns
The roller bodies of the needle-roller bearings for the loose gear wheel for 6th gear are available in various thicknesses. The roller body thickness increases in increments of 4 microns.
15. Work out which new needle-roller bearing to use for the loose gear wheel for 6th gear if the average radial play is not between 15 microns and 25 microns.
Example:
Actual size of the fitted roller body (the smallest needle-roller bearing available was fitted before taking measurements in accordance with instructions): 2.492 mm
Average measured bearing clearance: 30 microns
Required bearing clearance: 20 microns
Difference between actual and required bearing clearance: 30 microns - 20 microns = 10 microns
Since there are always two roller bodies for bearing clearance, the difference must be divided by 2.
Required size of fitted roller body: 10 microns / 2 microns = 5 microns. This gives a required size of 4 microns - given the specified increments for roller body thickness.
The needle-roller bearing to be fitted must have a roller body diameter of 2.496 mm.
16. Fit new needle-roller bearing and repeat the measurements. If the radial play is not between 15 microns and 25 microns, the needle-roller bearing must be replaced in accordance with the new measurement result.
Adjusting radial play for 5th gear
Measurement setup for 5th gear
1. Set the compressed air switch on the measuring device P 9746 to 0, then connect the measuring device P 9746 to the compressed air supply and set the pressure to 1 bar.
2. Clamp drive shaft in the measuring device P 9746.
3. Position measuring tower and measuring plate with respect to loose gear wheel for 5th gear and fix in place.
4. Position support rod on drive shaft and fix in place so that the measuring plate is slightly pre-tensioned.
5. Position retainer plate under measuring plate and fix in place at this position.
6. Position lifting cylinder under loose gear wheel for 5th gear.
7. Insert precision gauge with measuring base into measuring plate, fit upper measuring base on loose gear wheel toothing and fix precision gauge in place.
8. Set precision gauge to 0.
9. Set pressure switch to 1. This applies pressure to the lifting cylinder and presses the measuring ram up.
10. Read off play on precision gauge and write it down.
11. Set pressure switch to 0. This relieves the pressure in the lifting cylinder and pushes the measuring ram down.
This measurement must be performed three times. You can then calculate the mean measured value.
Example:
Measurement result 1: 32 microns
Measurement result 2: 30 microns
Measurement result 3: 28 microns
Mean value from measurements 1 to 3: (32 microns + 30 microns + 28 microns) / 3 = 30 microns
12. Lift up the measuring plate, turn the loose gear wheel for 5th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 4: 30 microns
Measurement result 5: 29 microns
Measurement result 6: 28 microns
Mean value from measurements 4 to 6: (30 microns + 29 microns + 28 microns) / 3 = 29 microns
13. Lift up the measuring plate, turn the loose gear wheel for 5th gear a further 120° and take another three measurements at this position.
Example:
Measurement result 7: 30 microns
Measurement result 8: 31 microns
Measurement result 9: 32 microns
Mean value from measurements 7 to 9: (30 microns + 31 microns + 32 microns) / 3 = 31 microns
14. Calculate the mean value for radial play on the loose gear wheel.
Example:
Mean value from measurements 1 to 3: 30 microns
Mean value from measurements 4 to 6: 29 microns
Mean value from measurements 7 to 9: 31 microns
Mean value of all measurements: (30 microns + 29 microns + 31 microns) / 3 = 30 microns
The roller bodies of the needle-roller bearings for the loose gear wheel for 5th gear are available in various thicknesses. The roller body thickness increases in increments of 4 microns.
15. Work out which new needle-roller bearing to use for the loose gear wheel for 5th gear if the average radial play is not between 15 microns and 25 microns.
Example:
Actual size of the fitted roller body (the smallest needle-roller bearing available was fitted before taking measurements in accordance with instructions): 2.500 mm
Average measured bearing clearance: 30 microns
Required bearing clearance: 20 microns
Difference between actual and required bearing clearance: 30 microns - 20 microns = 10 microns
Since there are always two roller bodies for bearing clearance, the difference must be divided by 2.
Required size of fitted roller body: 10 microns / 2 microns = 5 microns. This gives a required size of 4 microns - given the specified increments for roller body thickness.
The needle-roller bearing to be fitted must have a roller body diameter of 2.504 mm.
16. Fit new needle-roller bearing and repeat the measurements. If the radial play is not between 15 microns and 25 microns, the needle-roller bearing must be replaced in accordance with the new measurement result.
Subsequent work
1. Assemble drive shaft.
2. Assemble transmission.
3. Install transmission.
4. Fill with transmission oil.