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JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 26

Section F

Transmission

Section F

69 - 4

Service Procedures

69 - 4

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

5. ShiftMaster Diagnostics: Overview

There are several key elements to the ShiftMaster

Diagnostics tool. These can be seen labelled below. Each

element is explained in detail in later sections.

Menu Bar

Main Window

Page Display Area

Start/Stop Buttons

ECU Setup Page

Page List

LED Status Key

Status Bar

ECU Status Page Dashboard Page

S404250

Navigating within ShiftMaster Diagnostics

Navigation is designed to be via a mouse. On Laptop PCs

Note: This can be particularly useful for certain Laptop PCs

this may take the form of a small joystick or touch sensitive

where the mouse/joystick can be over-sensitive. Try out the

pad and some buttons, usually located near to the

following, it may come in useful one day.

keyboard.

There are two main methods of navigation described below;

As with most Windows based programs, it is possible to

navigate ShiftMaster Diagnostics using the keyboard by

·

Pressing the ALT key will cause the File option on the

pressing certain combinations of keys.

Menu Bar to be highlighted. You can then use the

arrow keys to navigate the menus.

·

Notice that all the menu items on the Menu Bar have a

letter that is underlined (e.g. the 'F' in File). Holding

down the ALT key and pressing the required letter key

will activate that option (i.e. either open the menu or

execute a function). For example, if you wish to open

the Preferences Dialogue this can be done by pressing

ALT + O (to open the Options menu) then ALT + P (to

execute the Preferences… option).

9803/3280

Issue 1

Section F

Transmission

Section F

69 - 5

Service Procedures

69 - 5

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

6. Menu Bar

File Menu

· English (British)

The File Menu contains and Exit option to close down the

· French (Standard)

program.

· German (Standard)

· Spanish (Modern Sort)

Note: The language option only effects text within the Main

Window (e.g. Page List, LED Status Key, etc…). At present

S404260

language support is not offered for the text within the Page

On exiting the program communications with both ECU and

displays.

DLA are shut down.

The Preferences Dialogue also offers the ability to change

Options Menu

the backg7round colour of the Page displays. Select the

Select either:

required backg7round colour using the radio buttons.

Start Diagnostics to commence communications with the

ShiftMaster ECU.

or

S404300

Note: When using a laptop PC it can often be difficult to see

the screen in bright sunlight. Changing the backg7round

colour can help improve the contrast (especially with the

different LED colours) and so make viewing the screen

easier. Examples of the different colours are shown below;

S404270

Stop Diagnostics to cease communications.

Clicking on the Preferences… option opens up the

Preference Dialogue.

S404310

S404320

S404280

S404330

From the Preferences Dialogue there is support for multiple

Once your preferences have been selected either:

languages. Use the drop-down menu and scroll bar to chose

the required language. Languages presently on offer are:

Click on

to apply them or click on

to leave them unchanged.

S404290

9803/3280

Issue 1

Section F

Transmission

Section F

69 - 6

Service Procedures

69 - 6

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

Window Menu

Fault Finding Guide: Provided to help the user to

Like most other Windows based programs where there are

understand how the PS760 gearbox electrical system

multiple sub-windows or Pages used, there are usually

operates. This Guide also offers advice on fault diagnosis

options to organise how they are laid-out. ShiftMaster

along with example scenarios, hints and tips.

Diagnostics is no different and offert the following options;

· Cascade

· Tile Horizontally

· Tile Vertically

Note: Laptop PCs, particularly older ones, tend to have a

low screen resolution. If this is the case then the Horizontal

S404370

and Vertical tile options will probably be of little use and

Cascade will offer the best advantage.

Selecting the About… option will bring up a window

Help Menu

showing the JCB part number and the version number of the

installed copy of ShiftMaster Diagnostics.

To assist the Service Engineer, ShiftMaster Diagnostics is

supplied with a set of documentary Guides. These Guides

can be accessed directly from within the ShiftMaster

Diagnostics tool itself, via the Help menu.

Note: All the Guides are provided in Adobe Acrobat PDF

format. In order to read these guides the user must first have

the Adobe Acrobat Reader installed on the PC. This

S404380

software is supplied on the JCB CD-ROM where full

installation instructions are provided.

At present these guides are as follows;

User Guide: This file is provided to explain how all the

functions of the ShiftMaster Diagnostics tool operate.

S404390

S404360

Troubleshooting Guide: Sometimes users may experience

problems with getting ShiftMaster Diagnostics to

7. Start/Stop Buttons

communicate properly with the ShiftMaster ECU. The

Trouble shooting Guide has been provided to explain

These offer the same function as the Start Diagnostics and

possible causes of problems with communications.

Stop Diagnostics options within the Options Menu.

To start the ShiftMaster Diagnostics tool communicating

with the ShiftMaster ECU simply click on the Start Button

(big green LED) at the top of the Main Window.

Similarly, click on the Stop Button (big red LED) to cease

communications.

S404240

S404400

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Issue 1

Section F

Transmission

Section F

69 - 7

Service Procedures

69 - 7

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

8. Page List

10. ECU Setup Page

In the top left corner of the main window is displayed a list of

This page displays crucial information about the ECU

pages which can be displayed.

configuration.

S404410

S404450

Clicking in the box next to the required page with make that

page appear in the main window display area. (A tick will

It is always useful to confirm that this is the correct

also appear in the box to show it is being displayed.)

configuration for the machine before commencing any fault

finding.

At any time the user may swap between displayed pages

simply by clicking on the title of the required page in the

The ECU Setup Page displays the following information;

page list.

ECU Part Number

This will display the part number of the connected

ShiftMaster ECU.

If there are communications errors present then this will

contain either;

a). 'NO DLA COMMS' if there are problems communication

with the DLA, or

b). 'NO ECU COMMS' if the DLA is working but the

ShiftMaster ECU is not responding.

S404420

9. Status Bar

Note: If communications problems are suspected then

please consult the accompanying Troubleshooting Guide

There are 2 items of interest displayed on the Status Bar,

for further information.

which is located along the bottom of the ShiftMaster

Diagnostics Main Window.

Hardware Version

This hardware version is a reference to the build level of the

Connected ECU: The type of ECU connected to the

electronics. Future developments may mean that hardware

ShiftMaster Diagnostics tool is indicated on the far left side

upgrades are required. This may effect which software can

of the Status bar.

be used.

Software Version

S404430

The software version refers to the issue level of the ECU

operating software. Again, future developments may require

software revisions.

CAN communications: Two small LEDs indicate data being

transmitted (red) and received (green) over the CAN

ECU Setup Description

communications link.

As well as its' operating software, the ShiftMaster ECU also

stores a group of Setup Data (or Settings). This Setup Data

is used to tailor how a certain ECU part number functions.

The Setup Data is loaded during the manufacturing process

S404440

and has been approved for use in the intended application.

These LEDs can be seen to be flashing rapidly as data is

Contained as part of the Setup Data is a Description. This

transported. This can be another useful aid to determining

Description is what is displayed here. The Engineer can use

the state of any established communications.

this description to verify that the correct Setup Data is being

used.

At present there is no service tool available to load new

Setup Data.

9803/3280

Issue 1

Section F

Transmission

Section F

69 - 8

Service Procedures

69 - 8

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

11. Dashboard

This offers a simple uncluttered display showing;

Information in this display is constantly updated in real-time.

(Some older PCs may experience a slight delay in updating

this page, but usually only less than one second.)

The left hand side shows the inputs to the ECU, their status

indicated by green LEDs.

The right hand side shows the outputs from the ECU, their

status shown by red LEDs.

S404460

Requested Gear

The exact colour of the LED indicates the status of that

This is the demand from the driver.

feature.

Selected Gear

A key in the bottom left corner of the main window explains

This is the actual gear being selected by the ECU.

the colours.

Note: The driver Request Gear is not always the same as

the Selected Gear, e.g. when the ECU blocks shifts when

offering protection.

Transmission Speed

This is the current transmission output speed which is

directly related to the road speed (through axle ratio and tyre

size). The transmission speed sensor is located next to the

S404480

output gear and detects the passing of the gear teeth. The

sensor has a fixed installation, no adjustment is necessary.

The following is a brief explanation of each feature. For

further information and examples of typical scenarios please

The Transmission Speed value is a frequency reading and is

refer to the accompanying Fault Finding Guide accessible

displayed in Hertz (Hz), or teeth per second.

via the Help menu.

This signal is used by the ECU to determine gear-shifting

Transmission Speed

and protection strategies.

This is exactly the same signal as explained in the previous

section.

12. ECU Status Page

Gears

This page gives a detailed picture of how the ECU is

Inputs: The items on the left show the signal lines

operating.

connected to the gear selection lever. This lever if the left

hand half of the control lever assembly mounted on the

steering column.

Outputs: The items on the right are the power signals going

down to the transmission solenoid valves. The LEDs will

indicate which solenoids are being energised. Error

detection on the output electrics is continually running. If any

output were to develop a fault (e.g. open circuit or short

circuit) then the LED will turn yellow. Fix the fault and the

LED will revert back to red.

During certain gear-shifts the ShiftMaster ECU will perform

electrical Modulation to improve gear-shift quality. The ECU

does this by adding delays to off-going and/or on-coming

clutches and so overlapping energised outputs. These

delays are in the order of a few hundred milli-seconds but it

is sometimes long enough to be observed on the status

LEDs. Thus, during certain shifts it is quite normal to observe

more than 2 outputs ON at any one time.

S404470

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Issue 1

Section F

Transmission

Section F

70 - 1

Service Procedures

70 - 1

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - Troubleshooting Guide

1. Introduction

2. Elementary Checks

If you are experiencing difficulties with getting ShiftMaster

Please make sure that the correct communications leads are

Diagnostics and your PC to communicate with a

being used and are not damaged in any way.

ShiftMaster ECU then please take a little time to read the

following information which has been compiled to guide

Non Communication with DLA

diagnosis of such problems.

In general, whenever there are problems communicating

with the DLA there will be an error message displayed.

To utilise any supporting ShiftMaster Service Tools requires

the use of the JCB Data Link Adaptor (DLA) which is part of

the standard JCB Electronic Service Tool Kit, part number

892/01033.

This software is intended for use on IBM Compatible

Personal Computers (PCs) running Windows 9x or

Windows2000 operating systems but is not compatible with

either earlier versions of Windows 3.x.

S404140

It is known that some laptop PCs can experience problems

More specifically, if communications can not be established

with serial communications.

with the DLA then the ECU Setup Page will display 'NO DLA

COMMS' where the ECU Part Number should be.

In a few rare cases the PCs hardware does not allow the

diagnostics software access to communications (COM)

ports.

JCB Service are in the process of compiling a

'recommended' list of laptops which we know to work

satisfactorily with JCB Software.

In the majority of cases conflicts are caused by either

S404150

software already running on the PC, or by certain 'driver'

Non Communication with ECU

files which hog the COM port(s).

If communications can not be established with the ECU then

the ECU Setup Page will display 'NO ECU COMMS' where

Note: a PC which has many users and uses is likely to

the ECU Part Number should be.

contain some redundant software and drivers.

If you do not feel technically competent to adjust PC

software & set-up, please enlist the help of someone

suitably trained before proceding.

S404160

Note: The ECU must be powered for communications to

work, i.e. the machine ignition must be ON (but the engine

need not be running).

9803/3280

Issue 1

Section F

Transmission

Section F

75 - 1

Propshafts

75 - 1

Propshafts

Removing and Replacing

When Removing

Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.

When Replacing

Upon reassembly, after lubricating sliding joints with JCB

MPL Grease, align the shafts against identification marks

previously made or, in the case of a shaft being renewed,

REAR

use the manufacturer's alignment markings.

Apply JCB Threadlocker and Sealer to threads of all flange

bolts.

Retaining straps C stretch with use, therefore these straps

must always be replaced with new ones.

The propshaft must have both ends exactly on the same

plane as shown at X. The yokes must not be at right angles

as at Y or at an intermediate angle as at Z.

B

Torque Settings

A

Item

Nm

kgf m

lbf ft

A

75 - 85

7.7 - 8.7

55 - 63

B

118

12

87

A396840

C

A

X

S232350

Y

A

A

Z

S157500

S189610

FRONT

9803/3280

Issue 1

Section F

Transmission

Section F

80 - 1

Front Axle - SD55, SD70

80 - 1

Removal and Replacement

K

C

-238.14

A

J

J

C

D

B

H

F

B

E

G

A401290

9803/3280

Issue 1

Section F

Transmission

Section F

80 - 3

Front Axle - SD55, SD70

80 - 3

Removal and Replacement (cont’d)

Replacement

Replacement is the reverse of the removal sequence.

! WARNING

Y

If, for whatever reason, a wheel stud is renewed, all the

studs for that wheel must be changed as a set, since the

remaining studs may have been damaged.

2-3-2-8

Whenever a wheel has been removed, check the wheel nut

torques every two hours until they stay correct.

Apply JCB Lock & Seal to the threads of bolts A.

The front axle must be shimmed to give a maximum fore and

aft movement of 0.5 mm (0.020 in).

Nylon shims must be fitted as follows:

AWS Machines

a Fit a 5.0 mm thick master shim (coloured blue) between

the front of the axle and the yoke plate as shown at X.

b Measure the fore and aft movement and subtract 0.5

mm to obtain the required shim thickness. Fit the

correct thickness shim between the rear of the axle and

the yoke plate as shown at Y.

X

2WS Machines

a Fit a 5.0 mm thick master shim (coloured blue) between

the rear of the axle and the yoke plate as shown at Y.

A258180

b Measure the fore and aft movement and subtract 0.5

mm to obtain the required shim thickness. Fit the

correct thickness shim between the front of the axle

and the yoke plate as shown at X.

Note 1: DO NOT fit more than 2 shims (including the master

shim).

Note 2: To assist assembly, use the double sided tape ring

supplied to retain the shims on the yoke plate.

If the setting of the steering proximity switch has been

disturbed, then complete the front axle proximity switch

setting procedure, see Section H, Service Procedures.

Torque Settings

Item

Nm

kgf m

lbf ft

A

79

8

58

D

680

69

500

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 1

Front Axle - SD55, SD70

81 - 1

Hub and Driveshaft - Dismantling

The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the

axle.

! WARNING

A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before

raising one end. Ensure the other end is securely

chocked. Do not rely solely on the machine hydraulics or

jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.

GEN 1-1

1

Disconnect the steering track rod. Drain oil from the

hub.

Note: The illustration shows a typical axle.

2

Remove screws A.

B

3

Lever the planet gear carrier B off the bearing carrier.

Clean off all traces of sealant from the mating faces or

remove ‘O’ ring as applicable.

A

S258220

4

Remove planet gears only if defective. Note that gears

can only be removed as assemblies, which comprise

the gear, the bearing and two 'L' shaped circlips. To

remove a planet gear, first remove the external circlip.

5

Pull off the planet gear.

6

The driveshaft thrust pad C is drilled and tapped M6 for

removal purposes.

C

255920

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 2

Front Axle - SD55, SD70

81 - 2

Hub and Driveshaft - Dismantling (cont'd)

7

Remove circlip D to allow the sun gear to be slid off the

drive shaft.

D

256010

8

To remove the ‘Verbus Ripp’ bolts E, it is necessary to

remove the spacer F. Revolve the spacer with a suitable

drift to align the holes in the spacer with the space

between the bolts.

E

F

9

Using two dowels and two heel bars, remove the spacer

using the method shown.

10

Remove the 'Verbus Ripp' bolts using a special tool

(part number 892/00333). These bolts are very tight and

care must be taken not to distort the bolt heads. Use as

short an extension bar as possible.

255930

11

Using 2 high grade M14 bolts as jacking screws,

remove the annulus carrier.

Note: Fretting between the hub swivel and annulus carrier

mating faces might be evident; this condition is normal, do

not attempt to repair. If the hub swivel and annulus carrier

are to be re-used, the carrier must be assembled in the same

angular position it was removed; match mark the hub swivel

and carrier before removing the carrier.

S258240

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 3

Front Axle - SD55, SD70

81 - 3

Hub and Driveshaft - Dismantling (cont'd)

12

Remove circlip G to separate the annulus ring from the

annulus carrier.

G

S248910

13

Pull off the bearing carrier together with the outer

bearing cone and its bearing cup. Withdraw the inner

bearing cup from the inboard side of the carrier.

Note: To prevent damaging the axle case inner seal, do not

lever against the half shaft. Place a tube over the half shaft

and lever against the tube, as shown at X.

S248920

X

A258390

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 4

Front Axle - SD55, SD70

81 - 4

Hub and Driveshaft - Dismantling (cont'd)

14

Pull off the inner bearing - see Note at step 13.

15

Remove and discard the seal.

Note: The inner bearing and oil seal may withdraw with the

bearing carrier.

S258260

16

Remove and discard the combination seal. When

assembling the axle, a new combination seal must be

used.

S248880

17

Mark position of top and bottom trunnions H and

remove. Withdraw the hub carrier.

H

Note 1: Trunnions may be removed easily by pumping

grease through the grease nipple.

S248890

H

18

Use adaptor 993/59500 with slide hammer tool

892/00224 and remove driveshaft seal and needle roller

bearing from the hub carrier.

S161460

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 5

Front Axle - SD55, SD70

81 - 5

Hub and Driveshaft - Dismantling (cont'd)

19

Use a puller to remove the trunnion seal and bearing.

S258270

20

Withdraw drive shaft.

21

Prise out drive shaft inner oil seal J.

22

Remove circlip K

23

Remove bearing using tool 892/00225.

K

J

255990

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 6

Front Axle - SD55, SD70

81 - 6

Hub and Driveshaft - Assembly

1

Tap drive shaft inner bearing into position and secure

with circlip K.

2

Fit new oil seal J. Pack grease between lips of seal.

3

Fit drive shaft, taking care to locate inner end into

splines of differential gears.

K

J

255990

4

Press new trunnion oil seal into position followed by the

bearing. Grease bearing and oil seal before fitting to

axle.

S258270

5

Fit driveshaft needle roller bearing to the hub carrier.

Pack the cavity between the oil seal lips with grease

and then fit the seal.

S161460

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 7

Front Axle - SD55, SD70

81 - 7

Hub and Driveshaft - Assembly (cont'd)

6

Locate hub carrier and fit bottom trunnion. Apply JCB

Lock and Seal (part no. 4101/0202) to the bottom

trunnion bolt threads, fit and tighten to 98Nm (72 lbf ft).

Fit top trunnion and leave top trunnion bolts finger tight.

S248890

7

Attach a spring balance to track rod swivel as shown

and note the reading. Tighten the top trunnion bolts to

eliminate end float but no bearing pre-load, ie no

increase in spring balance reading.

8

Refit top trunnion. Apply JCB Threadlocker and Sealer

to the top trunnion bolt threads, fit and tighten to 98 Nm

(72 lbf ft). Check spring balance reading which should

be 4.5 kgf (10 lbf) more than the reading recorded at fig.

7.

S248850

9

Lightly oil the inner wheel bearing. Assemble the inner

A267170

and outer bearing cups, and the inner bearing cone into

the bearing carrier.

A

10

Fit a new combination oil seal. Do not lubricate before

fitting. Drive the seal squarely into the carrier until the

locating lip is flush as shown at A.

11

Fit the bearing carrier onto the axle arm. Lightly oil the

outer wheel bearing race. Fit the bearing onto the axle

arm. Rotate the bearing during fitting.

S248920

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 8

Front Axle - SD55, SD70

81 - 8

Hub and Driveshaft - Assembly (cont'd)

12

Assemble the annulus ring to the annulus carrier.

Secure with the circlip G.

G

S248910

13

Fit annulus assembly in the same angular position as

removal (see Note, Dismantling, step 11) using new

'Verbus Ripp' bolts. Do not fully tighten bolts but allow

the bearing carrier to rock slightly. Measure seal drag

rolling force - see step 14.

Note: Steps 13 to 16 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool

is required. Refer to Service Tools.

S248540

14

To measure seal drag rolling force:

-

Refit the planet gear carrier - DO NOT FIT THE SUN

GEAR.

-

Use a spring balance and cord wrapped around the

planet carrier flange as shown.

-

Pull the spring balance so that the hub rotates, do

several times to let the seal bed in and record the

reading.

-

Remove planet gear carrier.

S248870

15

Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33

kgf m) and then measure rolling force - see step 16.

S248540

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 9

Front Axle - SD55, SD70

81 - 9

Hub and Driveshaft - Assembly (cont'd)

16

To measure rolling force:

-

Refit the planet gear carrier - DO NOT FIT THE SUN

GEAR. Use a spring balance and cord wrapped

around the planet gear carrier flange as shown. Pull

the spring balance so that the hub rotates and

record the reading.

-

To get the rolling force, subtract seal drag rolling

force (see step 14) from reading obtained at this

step, the result should be 64 to 117 N (14 to 26 lbf).

-

If the resulting figure is outside these limits check:

the seal is fitted correctly; and/or renew bearings if

necessary; and /or new fitted components.

S248870

-

Remove planet gear carrier.

17

Press the drive shaft thrust pad C (chamfered side

lowermost) into the recess in the planet carrier.

18

Fit new planet gears in place of any that were removed.

(See step 4 in 'Dismantling'). Secure with circlip.

Note: Make sure that the SMALL radius on the gear bearing

internal diameter is facing uppermost, that is at the circlip

end of the planet pin.

C

255920

19

Fit spacer and slide the sun wheel onto the driveshaft

and secure with circlip D. Apply a fillet of sealant

4102/0900 evenly around the bearing carrier as shown

X

at X.

Note: Some machines may have an ‘O’ ring instead of

sealant - where appropriate fit a new ‘O’ ring.

Note: The sun gear must be fitted with the 1.5 mm (0.060 in)

x 45° chamfer inboard.

D

S258230

9803/3280

Issue 1

Section F

Transmission

Section F

81 - 10

Front Axle - SD55, SD70

81 - 10

Hub and Driveshaft - Assembly (cont'd)

20

Fit the planet carrier onto the bearing carrier, ensuring

that the two tapped holes are in line with those on the

bearing carrier. Fit and torque tighten screws A to

56Nm (41Ibf ft; 5.7kgf m) after applying JCB Lock and

Seal to the threads.

Note: Do not strike the centre of the planet gear carrier when

fitting as this may dislodge the driveshaft thrust pad fitted at

step 17.

Re-fill hubs with the correct grade oil.

A

S258220

9803/3280

Issue 1

Section F

Transmission

Section F

82 - 1

Front Axle - SD55

82 - 1

Drive Head - Dismantling

ITL00670

9803/3280

Issue 1

Section F

Transmission

Section F

82 - 3

Front Axle - SD55

82 - 3

Drive Head - Assembly (cont’d)

ITL00670

9803/3280

Issue 1

Section F

Transmission

Section F

82 - 4

Front Axle - SD55

82 - 4

Drive Head - Assembly

The outline procedure below refers also to the following

6

Fit special bracket D to the drive-head housing using

aspects of the drivehead assembly, which are covered

two M10 x 30 nuts and bolts. Fit special tool support

separately in detail as sub topics later in this section:

pillar E to bracket D so that the fork end engages in

adapter C. Ensure that fork E is centrally located on

Pinion Depth Setting

adapter C. If necessary, re-align bracket D to suit.

Collapsible Spacer Assembly

Crown Wheel and Pinion Meshing

Note: Both the crownwheel 15 and pinion 20 and the bevel

gears 9 and 10 are matched and should be renewed as sets

if any of their components are damaged or excessively

worn. The two differential housing halves 8A and 8B are also

matched. Do not use unmatched halves.

E

Make sure all bearings are lightly oiled before fitting and

C

setting. Make sure bearings are rotated whilst being set.

1

Determine the correct thickness required for the shims

23, refer to Pinion Depth Setting.

D

B

2

Fit shims 23 behind new bearing cup 22.

3

Fit new pinion head bearing cone 22 onto pinion 20.

4

Install pinion and bearings into the drive head casing.

348030

Install largest available solid spacer 24 e.g (14.20 mm)

and fit pinion tail bearing 21 (lightly oiled). Do not fit the

oil seal 19 at this stage.

7

Fit dial test indicator (DTI) F. Ensure that the DTI is

mounted on the drive head and not on bracket D.

Note: It should be noted that the axle is assembled using a

solid spacer. However, in the absence of the special tools

required or the correct size solid spacer 24 it is acceptable

8

Set torque wrench G to 35 Nm (25.8 lbf ft) and measure

to fit a collapsible spacer, refer to Collapsible Spacer

the end float while rotating the shaft.

Assembly.

5

Fit special tool sleeve B and special pinion shaft

G

adapter C. Tighten adapter C to approximately 50 Nm,

making sure the pinion is free to rotate and there is end

float, this will prevent any damage to the bearing. If the

pinion is not free to rotate or there is no end float at this

stage check the bearing is fitted correctly. Also check

F

the correct size spacer has been fitted.

348040

9803/3280

Issue 1

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