A/S Training for TML REAR AXLE SYSTEM

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

CONTENTS

1.STRUCTURE

2.MAINTENANCE
1) DISASSEMBLY DRAWING OF REAR AXLE
3) DIFFERENTIAL CARRIER ASSEMBLY
4) DIFFERENTIAL CARRIER AND RING GEAR ASSEMBLY
5) DRIVE PINION AND CAGE ASSEMBLY
6) INSPECTION AND REPAIR
7) ASSEMBLY

3.TROUBLESHOOTING

4.Tighten Torque

5. Failure Analysis Manual for DRIVE AXLE CARRIER

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

1.Structure(1)

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

1.Structure(2)

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2. MAINTENANCE
1) DISASSEMBLY OF REAR AXLE(1)

DISASSEMBLY ORDER
1. AXLE SHAFT
2. PROPELLER SHAFT
3. DIFFERENTIAL CARRIER ASSEMBLY

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

1) DISASSEMBLY OF REAR AXLE(2)

DISASSEMBLY ORDER
(When reassembling, proceed as
reverse order of disassembly.)

1.Brake drum
2.Snap ring
3.Inner oil seal
4.Hub
5.Inner bearing
6.Outer bearing
7.Adjust nut
8.Lock washer
9.Bolt
10.Outer oil seal
11.Axle shaft
12.Stud-wheel

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)Differential carrier assembly

DISASSEMBLY ORDER
1.LOCK PLATE
2.BEARING CAP
3.ADJUSTING NUT
4.SIDE BEARING OUTER RACE
5.DIFFERENTIAL CARRIER AND
RING GEAR ASSEMBLY
6.DRIVE PINION AND CAGE ASSEMBL
7.SHIM
8.SNAP RING
9.PILOT BEARING

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

CAUTION ON DISASSEMBLY
Position mark

Position mark

Mark the position on right and left side of

side bearing to prevent mingled Mark the position for easy reassembly

Keep the side bearing outer race and

inner one separately Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

3)DIFFERENTIAL CARRIER AND RING GEAR ASSEMBLY

Position mark

CAUTION
Mark the position for
easy reassembly
of differential carrier
DISASSEMBLY ORDER
1.DIFFERENTIAL CARRIER
2.SIDE GEAR
3.TRUST WASHER
4.TRUST WASHER
5.DIFFERENTIAL PINION
6.SPIDER
7.RIGN GEAR, SIDE BEARING INNER RACE AND
DIFFERENTIAL CARRIER

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

4)DRIVE PINION AND CAGE ASSEMBLY

DISASSEMBLY ORDER
1.SPLIT PIN 6.COLLAR
2.FLANGE NUT 7.OUTER BEARING INNER RACE
3.FLANGE ASSEMBLY 8.DRIVE PINION CAGE
4.OIL SEAL 9.SPACER
5.OIL SEPEARTOR 10.DRIVE PINION, INNER BEARING INNER RACE

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

5)INSPECTION AND REPAIR

1)Visual inspection
-GEAR, BEARING, OIL SEAL, DIFFERENTIAL, DRIVE PINION CAGE

2)Replacement of ring gear 3)Replacement of differential carrier

a.Replace the ring gear together with a.Replace the differential carrier as an
drive pinion as a set assembly
b. When installing the ring gear, apply b.Install the side bearing by proper
the Loctite to ring gear screw hole tool.
and bolt threads and then tighten
the bolts.
Tightening torque : 31 ~ 35kgm

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

5)INSPECTION AND REPAIR

4)Replacement of drive pinion bearing

a. Remove the inner race and inner bearing by snap ring plier and bench press
b. Install the spacer into the inner bearing to protect the bearing.

5)Replacement of drive pinion pilot bearing

a. Remove the pilot bearing by snap ring plier and bench press.
-Measure the clearance -Measure the clearance -Measure the clearance -Measure the backlash
between the spider and between the side gear & between the side gear & between the side gear &
& differential pinion the differential carrier the axle shaft the differential pinion
-Maintenance standard : -Maintenance standard : -Maintenance standard : -Maintenance standard :
0.169~0.278 0.2 ~ 0.326 0.2 0.20 ~ 0.28
-Repair Limit : 0.3 -Repair Limit : 0.15~0.22

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

6)ASSEMBLY
1)Drive pinion and cage assembly
a.Assembly order
1.Outer bearing inner race
2.Oil Seal : Apply the liquid gasket(Loctite) → Adjust the bearing preload →
Install the oil seal
3.Drive pinion, Inner bearing, pilot bearing
4.Spacer for adjusting preload
5.Flange : Clean the inside of dust cover → Apply the grease → Apply the gear oil
to the oil seal
6.Flange nut : After installing the new nut, adjust the pinion bearing preload
- Adjust the drive pinion bearing preload by use of spacer with various thickness
Tightening torque : 55 ~ 75 kgm, Bearing preload : 2.0 ~ 3.3kg
Effective thickness of spacer( ㎜ ) : 16.450, 16.475, 16.000~17.025, 17.050
- Tighten the flange nut : Torque → 55~75kgm
- Adjust the bearing preload : 2.4 ~ 3.3kg(on cage bolt hole)

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

6)ASSEMBLY
2)Differential carrier and ring gear assembly
Ring gear, Side gear inner race & Differential carrier → Spider → Differential pinion
→ Differential pinion thrust washer → Side gear thrust washer → Side gear →
Differential carrier (Torque : 17 ~ 23Kgm)

3)Rear Axle
a.Install the pilot bearing
b.Install the differential carrier and ring gear assembly
c.Install the side bearing outer race
d.Install the adjusting nut
e. Install the bearing cap
- Adjust the side bearing preload on 4 place(Side bearing preload : 2.3~3.3kg)
- Inspect the backside of ring gear for run-out(Maintenance standard : 0.1 ~ 0.2)

Snap ring

a c
d

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

6)ASSEMBLY
3)Rear Axle
f.Install the pinion depth adjusting shim
Effective thickness of shims(mm) : 0.05, 0.1, 0.2, 1.0
Thickness of installed shim : 1.50
g.Install the drive pinion and cage assembly
1. Align the oil hole on cage with adjusting shim on carrier
(tighten torque : 105 ~ 13.5kgm)
2. Measure the backlash between the drive pinion and 4 ring gear
(backlash : 0.28 ~ 0.36 mm)
3. Inspection tooth engaging condition(If isn’t good condition, adjust)

g-1 g-2 g-3

f

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

6)ASSEMBLY
3)Rear Axle
4. Tooth engaging condition & Adjusting procedure
Tooth engaging Adjusting Tooth engaging Adjusting
Cause Cause
condition Procedure condition Procedure

1.Move the drive 1.Move the drive

pinion closely to drive pinion clos-
ring gear by ely to ring gear
reducing the by reducing the
The ring
The drive thickness of thickness of
gear is
pinion is pinion depth pinion depth
closely to
far from adjusting shims. adjusting shims.
the drive
ring gear 2.Adjust the back- 2.Adjust the back-
pinion
lash by moving lash by moving
the thickness of the ring gear
pinion depth away from drive
adjusting shims. pinion side.

1.Move the drive

1.Move the drive
pinion away
pinion away
from ring gear
from ring gear
by increasing The ring
The drive by reducing the
the thickness gear is
pinion is thickness of
of pinion depth far from
closely pinion depth
adjusting shims drive
to the adjusting shims.
2.Adjust the back- pinion
ring gear 2.Adjust the back-
lash by moving
lash by moving
the ring gear
the ring gear
away from
to drive pinion
drive pinion
side.
side.
Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

6)ASSEMBLY
3)Rear Axle
5. Tighten the bearing cap bolt(Torque : 38.7 ~ 52.6kgm)
6. Lock the cap bolt with lock plate
7. Lock the adjusting nut with lock plate
8. Apply the liquid gasket to the cage and carrier fitting surface
h. Install the drive pinion and cage assembly

g-6
g-5

Liquid
Shim gasket

Tongil Heavy
g-7 g-8 Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

3. TROUBLESHOOTING
Troubles Causes Measures

Bearing is worn or loose. Replace.

Noise from the axle Gear is worn and backlash is increased. Adjust or replace.
housing while
operating the machine.
Taper roller bearing is loose. Adjust.

Hypoid gear is not adjusted properly. Adjust.

Differential gear or pinion is worn or damaged. Replace.

Side gear and pinion thrust washer are worn. Replace.

Replace.
Noise of whistling Gear backlash of differential spider exceeds the
when traveling the standard value.
curved roads.
Side thrust washer exceeds the standard value. Replace.

Replace.
Clearance between differential pinion and spider
exceeds the standard value.

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

4. Tighten Torque

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

5. Failure Analysis Manual for DRIVE AXLE CARRIER

1)The general cause of axle carrier damage
- Improper application
- Improper usage
- Improper maintenance
- Wrong design and/or production

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅰ)Spinout damage
- Major cause : excessive usage of differential gear
- Usually Spinout occurs during as following condition
a) Backing under a trailer
b) Starting on a slipping surface
c) Traveling on a slipping surface

slip surface

good surface

slip surface

good surface

Single Axle Spinout Tandem Axle Spinout

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

- Example of Spinout damage of Tandem axle

B
A

D
C
Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

- The pictures of claimed parts due to Spinout

6 7 8

11
9
10 Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

- The pictures of claimed parts due to Spinout

12

13

Tongil Heavy
14 Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

- The countermeasure to prevent Spinout damage
a) Tandem axle :
Using inter differential lock system
b) Single axle :
Using the vehicle carefully
(Drop the Engine RPM when wheel is idled,
Towing the vehicle if the vehicle don’t move without excessive engine
power)

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅱ)Shock damage
- Major cause : Overload higher than axle capacity
- Usually Shock occurs during as following condition
a) Backing under a trailer
b) Hitting dry pavement with a spinning wheel
c) Missing a shift
d) Popping the clutch
e) Locking the inter differential during a spinout
- The pictures of claimed parts due to Shock damage

16 17 18 20

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅱ)Shock damage
- The pictures of claimed parts due to Shock damage

21 22 23

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅲ)Fatigue failure
- Major cause : Continuous shock load , Continuous over load
- The general type of Fatigue
a) Surface or Contact Fatigue
b) Torsion Fatigue
c) Bending Fatigue
- The pictures of claimed parts due to surface fatigue

29 30 31

Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅲ)Fatigue failure
- The pictures of claimed parts due to surface fatigue

32 33 34

37

35 36 Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅲ)Fatigue failure
- The pictures of claimed parts due to torsion fatigue

35 36
ⅲ)Fatigue failure
- The pictures of claimed parts due to bending fatigue

42

40 41
Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅳ)Lubrication failure
- The pictures of claimed parts due to lubrication failure

48 49 50

Tongil Heavy
52 53 Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅳ) Lubrication failure
- The pictures of claimed parts due to lubrication failure

58
54 55

63
59 61
Tongil Heavy
Industry Co., Ltd
A/S Training for TML REAR AXLE SYSTEM

2)The general type of axle carrier damage

ⅳ) Lubrication failure
- The pictures of claimed parts due to lubrication fatigue

68
64 66

69 70

Tongil Heavy
Industry Co., Ltd