Removing & Servicing The Crown Wheel And Pinion - PRM NEWAGE 415 Series Workshop Manual

REMOVING & SERVICING THE CROWN WHEEL AND PINION.
1. Remove the Drain Plug (A1) and drain the Axle Oil.
2. Remove both Axle Arm assemblies by removing 12 Bolts per side (D20). Withdraw the Plan-
et Carrier Assembly (see Section C), and Sun Gear (C9).
3. Remove 10 Bolts (E8) around the Pinion Cartridge. Using two M10 extraction Bolts (not
supplied), remove the Crown Wheel/Differential assembly through the Pinion Cartridge ap-
erture.
4. Remove the Pinion Nut (E12) from the Pinion Shaft (E1), along with the Washer (E11), and
the Coupling (E10).
5. Unpein 2 Adjuster Nuts (B10) and remove. Differential assembly will now be free to remove
from the Pinion Cartridge.
6. Drift Pinion (E1) through Cartridge and Inspect the Bearings (E2) for wear and damage. If
the inner Bearing on the Pinion head needs replacing, use a Bearing puller to extract the
cone. If the Bearing Cups or Oil Seals need replacing, they can be pressed or drifted out of
the Cartridge housing. Take care not to damage the Shims positioned behind the Bearing
Cup.
IMPORTANT: If any components are replaced a new Collapsible Spacer (E6) & Pinion
Nut (E12) must be used and the Crown Wheel/Pinion marking and backlash reset.
7. If the Crown Wheel and Pinion or Pinion Head Bearing (E2) are replaced, the following pro-
cedure needs to be carried out:
8. To check Shim size
(a) Note the new Pinion (E1) mounting distance (M.D.) on the head. (Approximately
87.5mm)
(b) Measure the new overall width of Pinion Head Bearing (E2). (Approximately
22.2mm)
(c) Note Pinion Cartridge (E7) mounting distance (Constant for 415 = 110.35mm).
(d) Shim thickness (E3, E4, E5) = 110.35 -(a)-(b) e.g. For theoretical normal shims:
9. Reassemble and tighten the Pinion Nut (E12) until the Collapsible Spacer (E6) collapses and
all the end float between the Pinion Bearings is removed. Note, the initial collapsed torque
on wrench should not be less than 245 Nm (180 lb.ft).
10. Continue to tighten the Pinion Nut until a pre-load of 59-98N (22lbf) for new Bearings, or
29.5-59N (6.6-13.2lbf) for used Bearings is obtained. The pre-load can be measured by bind-
ing a piece of string around the Coupling (E10) and measuring the load to turn the Coupling
110 - 22.2 - 87.5 = 0.65mm
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