Note: When replacing any of the components listed below, the tapered roller bearing preload must be adjusted.
- Gearbox housing
- Clutch housing
- Differential cup
- Tapered roller bearing and bearing outer ring
- Thrust washer
- Washer 75mm
1. Knock out the outer bearing race and thrust washer from the gearbox housing (see below).
Note: Press in the thrust washer only from the gearbox housing side.
Caution: Do not reuse the thrust washer after the outer race has been knocked out.
Note: If the bearing outer race was pressed out by heating the clutch housing, allow the gearbox to cool to room temperature before adjusting the tapered roller bearing preload.
2. First try pressing in a thrust washer of the same size.
Caution: Use only one thrust washer.
3. After pressing in the thrust washer, press the outer bearing ring into the gearbox housing (see above).
Note:
- Press in the outer bearing ring without tilting it.
- Make sure there is no gap between the bearing outer race, thrust washer or 75mm washer and the crankcase.
4. With the secondary and intermediate shafts removed, install the differential assembly and tighten the clutch housing and gearbox bolts.
Note: It is not necessary to apply sealant between the crankcases.
- tightening torque: 8x1.25 mm, 27 Nm (2.8 kgf/m)
5. Rotate the differential assembly in both directions to seat the tapered roller bearings.
6. Using a special tool and a torque wrench, measure the starting torque of the differential assembly.
- Standard: 1.4-2.5 Nm (14-16 kgf/cm)
Note:
- Measure the preload of the tapered roller bearing at normal room temperature.
- Measure the tapered roller bearing preload in both directions.
7. If the tapered roller bearing preload is different from the standard, select a thrust washer that will provide the required preload from the following table.
Note: When changing to the next larger or smaller thrust washer size, the tapered roller bearing preload changes by approximately 0.3-0.4 Nm (3-4 kgf/cm).
Thrust washer
| Catalogue number | Thickness | |
| A | 41381-РХ5-В00 | 1.90 mm |
| IN | 41382-РХ5-В00 | 1.93 mm |
| WITH | 41383-РХ5-В00 | 1.96 mm |
| D | 41384-РХ5-В00 | 1.99 mm |
| E | 41385-РХ5-В00 | 2.02 mm |
| F | 41386-РХ5-В00 | 2.05 mm |
| G | 41387-РХ5-В00 | 2.08 mm |
| N | 41388-РХ5-В00 | 2.11 mm |
| 1 | 41389-РХ5-В00 | 2.14 mm |
| J | 41390-РХ5-В00 | 2.17 mm |
| TO | 41391-РХ5-В00 | 2.20 mm |
| L | 41392-РХ5-В00 | 2.23 mm |
| M | 41393-РХ5-В00 | 2.26 mm |
| N | 41394-РХ5-В00 | 2.29 mm |
| ABOUT | 41395-РХ5-В00 | 2.32 mm |
| R | 41396-РХ5-В00 | 2.35 mm |
| Q | 41397-РХ5-В00 | 2.38 mm |
| R | 41398-РХ5-В00 | 2.41 mm |
| S | 41399-РХ5-В00 | 2.44 mm |
| T | 41400-РХ5-В00 | 2.47 mm |
| AA | 41873-РХ5-В00 | 1.66 mm |
| AB | 41874-РХ5-В00 | 1.69 mm |
| AC | 41875-РХ5-В00 | 1.72 mm |
| AD | 41876-РХ5-В00 | 1.75 mm |
| AE | 41877-РХ5-В00 | 1.78 mm |
| AF | 41878-РХ5-В00 | 1.81 mm |
| AG | 41879-РХ5-В00 | 1.84 mm |
| AN | 41880-РХ5-В00 | 1.87 mm |
8. Recheck the tapered roller bearing preload
9. How to select the correct thrust washer:
- 1) Compare the preload of the tapered roller bearing provided by the removed thrust washer with the standard preload of 1.4-2.5 Nm (14-16 kgf/cm).
- 2) If the measured preload of the tapered roller bearing is less than the standard, subtract the measured preload from the standard.
If the measured preload of the tapered roller bearing is greater than the standard, subtract the standard from the measured preload.
For example, in the case of a 2.17 mm thrust washer:
- 3) When moving to a thrust washer of the next larger or smaller size, the preload of the tapered roller bearing changes by approximately 0.3-0.4 Nm (3-4 kgf/cm).
In example (A), the measured preload of the tapered roller bearing was 1.9 Nm (20 kgf/cm) less than standard, so you need a thrust washer five sizes thicker than standard (try a 2.32 mm thick thrust washer and recheck).
In example (B), the measured preload was 0.8 Nm (8 kgf/cm) greater than standard, so you need a thrust washer two sizes thinner than standard (try a 2.1 mm thick thrust washer and recheck).