Main gear reducer design (models 140 28/032/033 until 05/31/94, 140.042/043/063/1 and a differential diameter of 210 mm)
A - Standard version; B - Version with ASR; C - Version with ASD; 11a, 43e, 46b - Tapered roller bearing outer races; 11b, 43d, 46a - Tapered roller bearing inner races; 13 - Differential; 13a, 27a, 56, 56b - Bolts; 25, 42 - O-rings; 26, 45, 48 - Gaskets; 27b, 27c, 27d - Bearing caps; 30 - Retaining ring; 31 b - Rings; 33, 33a, 33b - Drive shaft flanges; 40 - Nut; 41, 41a - Drive gear flanges; 43a - Pressure plate; 44 - Bushing; 47 - Drive gear; 47a - Driven gear; 49 - ABS rotor; 50 - Reducer; 54 - Rear cover of the gearbox; 55 - Breather; 32, 32a, 70j - Oil seals; 70l - Hydraulic tube
Disassembly
1. Remove the gearbox (50). Secure it in a vise.
2. Remove the back cover (54).
3. Remove retaining ring (30) from both flanges of the drive shafts (33) / (33a) / (33b).
4. Remove the drive shaft flanges.
5. On models with ASD/ASR, remove the ball bearings from the flanges.
6. On models without ASD, remove the rings (31b).
7. On models with ASD, remove the hydraulic tube (70l).
8. Remove bearing caps (27b) / (27c) / (27d), mark them with spacers (260).
9. Remove differential (13) from the gearbox.
10. Remove the left and right oil seals (32) / (32a), (70j) from bearing caps.
11. Press out both outer races (11a) bearings from bearing caps.
12. Press out both inner rings (11b) bearings from bearing caps.
13. Loosen and unscrew the bolts (13a) driven gear mountings (47a)..
14. Carefully remove the driven gear from the differential (13).
15. Loosen and unscrew the nut (40) flange mounting (41) / (41a).
16. Remove the flange (41) / (41a).
17. Press out the drive gear (47) from the gearbox.
18. Press out the radial o-ring (42) from the gearbox.
19. Remove the tapered roller bearing inner race (43d) with pressure plate (43a).
20. Remove the tapered roller bearing outer race (46b), (43e) and gasket (45) from the gearbox.
21. Remove bushing (44) with gasket (48) from the drive gear.
22. Remove the ABS rotor (49) from pinion (47).
Examination
1. Check all gearbox parts for wear and replace if necessary.
2. Check the host (47) and driven (47a) gears for correct digital numbering.
Assembly and adjustment
1. Press in the bearing inner race (46a) on the drive gear (47).
2. Press in the ABS rotor (49) on the drive gear (47).
3. Calculate the gasket thickness (45) and install it in the gearbox.
4. Install outer rings (46b), (43e) into the reducer.
5. Install bushing (44) with gasket (48) on both sides of the drive gear.
6. Insert pinion (47) into the reducer (50).
7. Fix the pressure plate (43a) on the inner ring of a tapered roller bearing (43d).
8. Insert the tapered roller bearing inner race (43d) on the drive gear and press it together with the O-ring (42).
9. Install the flange (41) / (41a) on the drive gear and tighten the nut (40).
10. Adjust the friction torque in the pinion bearing.
11. Check the adjusting distance of the drive gear.
12. Tighten the nut (40).
13. Fix the driven gear (47a) on the differential (13).
14. Press in the tapered roller bearing inner race (11b) to the differential.
15. Press in the outer race of the tapered roller bearing (11a) to the differential.
16. Press in the seals (32) / (32a), (70j) into the reducer (50) and insert differential (13).
17. Install retaining ring (30) on the flange.
18. Check and adjust flange clearance.
19. Attach the cover (54).
20. Replace breather (55) on the gearbox (50).
21. Further assembly and installation are carried out in the reverse order of disassembly and removal.
Technical data:
1. Permissible deviation from the adjustment distance at the end of the pinion is -0.02/+0.01 mm.
2. The gap between the flange and the gearbox housing is 0.03-0.3 mm.
3. The volume of the filled oil is 1.3 l.
4. Friction torque in the pinion bearing 125-150 Nm.