T-276 Two-Speed Carrier Mounted Input Transmission Transmission montée en entrée de nez de pont à deux vitesses

Transcription

1 TM T-276 Two-Speed Carrier Mounted Input Transmission Transmission montée en entrée de nez de pont à deux vitesses Maintenance Manual MM5.2 Manuel de maintenance MM5.2 Issued Edité Octobre 03 Models / Modèles Non-Planetary Rigid Axles JH-150 TA362 TA372 Planetary Rigid Axles PR100 PR150 PRTA592 PRTA673 PRTS205 PRTS596 TA279 Planetary Steer Axles PSTM596 PSTC824 PSTM824

2 Service Notes Service This Notes maintenance manual describes the correct service and repair procedures for all AxleTech T-276 two-speed carrier mounted input transmissions. The information contained in this manual was current at time of printing and is subject to change without notice or liability. You must follow your company procedures when you service or repair equipment or components. You must understand all procedures and instructions before you begin to work on a unit. Some procedures require the use of special tools for safe and correct service. Failure to use special tools when required can cause serious personal injury to service personnel, as well as damage equipment and components. The instructions contained in this Field Maintenance Manual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair and replacement of the AxleTech product described herein. Installation, maintenance and replacement of such products require a high degree of skill and experience. The consequences of improper installation, maintenance or replacement (including the use of inferior or substandard components) are grave and can result in product failure and resulting loss of control of the vehicle, possible injury to or death of persons and/or possible future or additional axle damage. AxleTech does not authorize anyone other than highly skilled and experienced individuals to attempt to utilize the instructions contained in this Manual for the installation, maintenance or replacement of the product described herein, and AxleTech shall have no liability of any kind for damages arising out of (or in connection with) any other use of the information contained in this Manual. AxleTech International uses the following notations to warn the user of possible safety problems and to provide information that will prevent damage to equipment and components. NOTE WARNING CAUTION How to Order A WARNING indicates a procedure that you must follow exactly to avoid serious personal injury. A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components. Serious personal injury can also occur. This symbol indicates that fasteners must be tightened to a specific torque. A NOTE indicates an operation, procedure or instruction that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier. Order items from AxleTech International. Phone orders are also accepted by calling AxleTech International s Customer Service Center at or send a fax to

3 Table of Contents Exploded View i Section 1: Introduction T-276 Two-Speed Transmission Section 2: Disassembly Transmission Section 3: Prepare Parts for Assembly Prepare Parts for Assembly Clean Ground or Polished Parts Remove Gasket Material from Parts Drying Cleaned Parts Prevent Corrosion Inspect Parts Repair Silicone (RTV) Gasket Material Application Section 4: Assembly Input Drive Pinion and Motor Adapter Sub-Assembly Transmission Case-to-Differential Carrier Installation Adjusting Idler Shaft Bearings Assemble Low Speed Driven Gear Assemble Shift Components Idler, Cover and Input Pinion Assembly Section 5: Specifications T-276 Torque Specs Oil Specifications T-276 Lube Recommendation Oil Change Intervals

4 Exploded View Exploded View a

5 Exploded View 1 Bearing Cup 2 Breather Assembly 3 Transmission Case 4 Bearing Cup 5 Oil Seal Assembly 6 Low Speed Driven Gear 7 Bushing 8 Detent Ball 9 Spring 10 Clutch Adapter 11 Clutch Adapter Nut 12 Set Screw 13 Sliding Shift Collar 14 Input Drive Pinion 15 Bearing Cone 16 Bearing Cup 17 Gasket 18 Spacers 19 Cover 20 Ball 21 Spring 22 Lock Washer 23 Shift Shaft Detent Screw 24 Input Adapter 25 Stud 26 Washer 27 Stud Nut 28 Oil Seal 29 Locknut 30 Bearing Cup 31 Bearing Cone 32 Washer 33 Input Locknut 34 Capscrew 35 Cover 36 Capscrew 37 Washer 38 Front Idler Bearing Cap 39 Shims 40 Front Idler Bearing Cup 41 Bearing Cone 42 Capscrew 43 Dowel 44 Idler Gear 45 Protector 46 Shift Shaft 47 Shift Fork 48 Set Screw 49 Lock Wire 50 Idler Pinion 51 Key 52 Bearing Cone 53 Rear Idler Bearing Cup 54 Capscrew 55 Flat Washer 56 Plug 57 Washer 58 Nut 59 Rear Idler Bearing Cap 60 Washer 61 Capscrew 62 Axle Bevel Pinion Maintenance Manual MM5.2 Copyright 2003 Issued AxleTech International Page i

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7 Section 1 Introduction Section Introduction 1 Description: T-276 Two-Speed Transmission The AxleTech T-276 is a carrier input mounted two-speed transmission that provides for a hydraulic motor to be directly mounted to several different axle models. Figure 1.1. Figure 1.1 Hydraulic motor mounts here. The T-276 provides ability for high torque multiplication in low range while permitting higher vehicle travel speed. The transmission has been supplied on several different carrier models including the F-140, H-140, H-150 and H-172 single-speed carrier models. Figure 1.2. Figure 1.2 CARRIER T-276 TRANSMISSION a Some models were even supplied as mid ship mounted to the vehicle frames and propshafts were connected to the drive axles. The T-276 has been available with various low ratios including 6.800, 5.938, and 3.033:1.0. High ratio is 1.0:1.0. There is a neutral position in the shift linkage to permit unpowered vehicle travel with the proper precautions taken in vehicle transport. Hydraulic motor mounts include several input mounting/ spline options. Typical hydraulic motor options include S.A.E. C and D four bolt mounts. Input spline options include 10T, 13T, 14T, 20T, 21T and 23T with different pitches. CAUTION The T-276 has its own oil reservoir within its sealed unit in the most popular options and must be filled separately from the axle/carrier oil lubrication. Figure 1.3. Figure " HI NEUTRAL 1.375".437" LO COVER CASE SHIFT FORK SHIFT SHAFT LOW SPEED DRIVEN GEAR BALL SPRING CLUTCH ADAPTER SLIDING COLLAR a a NOTE: This view shows the idler shaft rotated down 90 degrees from actual position. Maintenance Manual MM5.2 Copyright 2003 Issued AxleTech International Page 1

8 Section 2 Disassembly Section Disassembly 2 WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. Transmission NOTE: Most maintenance work can be performed by removal of the transmission cover, but if the hypoid pinion and/or pinion bearings need replacement, it will be necessary to remove the complete transmission and differential assembly from the axle. Steps below are based on oil having been drained, hydraulic motor removed, and shift linkage removed. 1. Remove shift shaft detent screw, spring and ball. 2. Drive dowels out of cover into case flange. Remove nuts, washers and capscrews from cover-to-case joint. 3. Remove cover. The input adapter and input drive pinion assembly will come off with the cover. 4. Remove the idler gear and pinion assembly 5. Remove the shift shaft, shift fork and sliding shift collar. NOTE: The sliding shift collar has a lock-up feature that may require some rotation of the collar for spline alignment to allow removal. 6. Remove the three detent balls and springs from the clutch adapter. If any of the balls fell out previously, be sure to retrieve before re-assembly. 7. Remove the clutch adapter nut. The nut is hex inches (47.63 mm) across flats. NOTE: Some models have a set screw in the clutch adapter that must be removed first. 9. Oil seal can be removed from case. 10. Outer pinion bearing cone can be removed for inspection. 11. If the hypoid pinion needs to be replaced and/or the transmission case must be removed, it is necessary to first disassemble the differential (remove the differential case and ring gear assembly). The roller bearing on the inner end of the hypoid pinion will interfere with the ring gear and prevent removal of the transmission case and hypoid pinion assembly if the ring gear was not removed previously. See maintenance manual #5 regarding differential maintenance procedures. The transmission case also functions as the hypoid pinion bearing cage. 12. If idler shaft bearings are worn or damaged, remove bearing cones from idler shaft. If new idler shaft bearings will be installed, then remove the original bearing cups as follows: A. Rear idler bearing cup: Remove capscrews and washers. Remove rear idler bearing cap, then remove the bearing cup. B. Front idler bearing cup: Remove capscrews and washers. Remove front idler bearing cap and shims, then remove bearing cup. 13. If idler gear is worn or damaged, remove the gear and key from the idler shaft. 14. Disassemble motor adapter and input drive pinion from cover. A. Remove stud nuts and washers, then remove adapter and pinion assembly. B. Unlock the locking tab of the input locknut, then remove nut and washer. C. Press out the input drive pinion. If no press is available, use plastic mallet to drive the pinion out taking care not to damage the threaded end. D. Remove bearing cones and spacers. Keep inner and outer bearing cones separated to later install in original locations if bearings are not replaced. E. If input bearings are worn or damaged, remove inner and outer bearing cups from the adapter. 8. Remove clutch adapter and low speed driven gear. NOTE: The hypoid pinion spline has a slight helix. It may be necessary to force the adapter off the pinion spline. Bronze bushing in bore of driven gear cannot be purchased separately since it is finish machined after pressing into gear. Copyright 2003 Maintenance Manual MM5.2 Page 2 AxleTech International Issued 10-03

9 Section 3 Prepare Parts for Assembly Section 3Parts for Assembly Prepare Parts for Assembly Clean Ground or Polished Parts WARNING Always wear safe eye protection when performing vehicle maintenance or service. Solvent cleaners can be flammable, poisonous, and cause burns. To avoid personal injury, you must carefully follow the manufacturer s product instructions. Wear safe eye protection. Wear clothing that protects your skin. Work in a well-ventilated area. Never use gasoline or solvents that contain gasoline. Gasoline can explode. Use a cleaning solvent to clean ground or polished parts or surfaces. Kerosene or diesel fuel oil can be used for this purpose NEVER USE GASOLINE. Do NOT clean ground or polished parts in a hot solution tank, steam or alkaline solution. Remove Gasket Material from Parts Use care to avoid damage to finish machined surfaces. Drying Cleaned Parts Dry parts immediately after cleaning. Use soft clean paper or wiping rags that are free of any abrasive material. Bearings should never be dried by spinning with compressed air. 3. Inspect spur gears for wear or damage. Gears that are pitted, galled, worn or broken through the case hardening should be replaced. Inspect bushing in low speed driven gear; if bushing is worn or damaged, it is necessary to replace the gear and bushing assembly you cannot purchase the bushing separately since it is finish machined after pressing into the gear. 4. Inspect clutch engagement teeth of input drive pinion and low speed driven gear. Replace if worn, chipped or damaged. 5. Inspect internal spline of input drive pinion for wear or damage. Repair Replace worn or damaged parts. Following are some examples to check for repair or replacement: 1. Replace any fastener if corners of the head or nut are rounded. Replace all lock washers. 2. Replace gaskets and oil seals 3. Clean old liquid gasket material from mating flanges. Avoid scratching the machined surfaces. 4. Remove any nicks, mars and burrs from machined surfaces. Use a fine file, India stone or emery cloth for this purpose. 5. Clean and repair threads of fasteners and tapped holes. Use a die or tap of correct size or a fine file for this purpose. 6. Verify studs in the cover (for motor adapter mounting) are tight. Prevent Corrosion Apply a light lubricant to clean and dried machined surfaces to prevent corrosion. If parts are to be stored, wrap the parts in special paper or other material designed to prevent corrosion. Inspect Parts 1. Inspect all bearing cups and cones; replace if wear, pitting, or damage is observed. Use suitable bearing pullers or a hydraulic press and sleeve for removal. Avoid use of drifts and hammers which may mutilate or distort the part. 2. Inspect shift shaft, shift fork, shift clutch collar, and clutch adapter. Replace if clutch engagement teeth are worn, chipped or mutilated. Maintenance Manual MM5.2 Copyright 2003 Issued AxleTech International Page 3

10 Section 3 Prepare Parts for Assembly Silicone (RTV) Gasket Material Application 1. Remove old gasket material from both surfaces. Clean and dry the surfaces. WARNING Some acid vapor is present when silicone gasket material is applied; make sure there is good ventilation in the work area. If silicone gasket material gets in your eyes, flush with water for 15 minutes. Have your eyes checked by a doctor. 2. Apply a inch (3.18 mm) diameter continuous bead of silicone gasket material around one of the surface. Also apply gasket material around the edge of all fastener holes on that surface. Figure 3.1. Figure " (3.18 MM) DIAMETER SILICONE GASKET MATERIAL BEAD a 3. Assemble the components immediately to permit the gasket material to compress evenly between the parts. 4. Wait 20 minutes before filling the assembly with oil. Copyright 2003 Maintenance Manual MM5.2 Page 4 AxleTech International Issued 10-03

11 Section 4 Assembly Section Assembly 4 Input Drive Pinion and Motor Adapter Sub-Assembly NOTE: Inner and outer bearings are same part numbers. If original bearings are reused, they should be installed in original locations. 1. Press bearing cups into cup bores of hydraulic motor adapter until seated firmly against the shoulders. 2. Press inner bearing cone to shoulder of input drive pinion. 3. Apply small amount of gear lube to bearing rollers. Install the drive pinion and inner bearing into the motor adapter. 4. Install the original bearing spacers, then the outer bearing cone with rollers lightly lubed. 5. Install the input bearing washer and adjusting nut. 6. Tighten adjusting nut until rotating torque of the input pinion is 5 to 15 lb-in (0.6 to 1.7 N m). The rotating torque can be checked by grasping the pinion in soft bronze jaws, then wrap a string around the pilot portion of the motor adapter and pull horizontally with a spring scale. Reading to be taken while adapter is rotating (not the start up pull). Example: Adapter pilot O.D. is inches (13.17 cm), so radius is 2.59 inches (6.58 cm) then a pull of 5 lb (22.25 N) is 13 lb-in (1.5 N m) rotating torque (5 x 2.59 or x ). The rotating torque can be altered by adding or the removal of thin bearing spacer/shims located between the bearing cones. T 7. When the bearing preload is adjusted within the 5 to 15 lb-in (0.6 to 1.7 N m) range, lock the adjusting nut by driving a part of the nut s outer thin flange into the slots of the input pinion. T 8. Set this sub-assembly aside for later installation into the cover. Transmission Case-to-Differential Carrier Installation 1. If rear idler bearing cap and bearing cup was removed previously, install bearing cup. Apply a inch (3.18 mm) diameter bead of liquid gasket to case and install the rear idler bearing cap, capscrews and lock washers. Tighten the capscrews to lb-ft ( N m). T If the transmission case was previously removed from the differential carrier for installation of a new hypoid pinion or pinion bearings, the proper pinion bearing preload adjustment procedure is shown in manual #5. However, the transmission case serves as the pinion cage shown in manual #5. This instruction will assume the necessary procedures have been performed to select the proper pinion bearing spacers (for bearing pre-load) and to select the proper shim pack between the transmission case and carrier housing (for hypoid gear tooth contact pattern). 2. Install new oil seal in bore of transmission case. 3. Apply non-hardening sealant to top and bottom of shim pack (between case and carrier). Install the transmission case and shim pack to the carrier. Install the capscrews and washers, tighten to lb-ft ( N m). T Adjusting Idler Shaft Bearings 1. Install idler gear and key on the idler shaft. 2. Press the front and rear bearing cones on the idler shaft until fully seated. 3. Install the idler shaft assembly into the transmission case (case is oriented with opening facing upward). NOTE: This is temporary. 4. Install the transmission cover with new gasket onto the case using six capscrews and nuts. Tighten to lb-ft (54-75 N m). T NOTE: This is temporary. 5. Install front idler bearing cup, front idler bearing cap, the original shim pack and the four capscrews. Tighten to lb-ft ( N m). T NOTE: This is temporary. 6. Rotate the idler shaft assembly. Check the end play of the idler shaft assembly (reach through the opening where the input pinion will be installed later). The proper end play is to inch (0.000 to mm). Add or remove shims from under the front idler bearing cap to alter the end play (adding shims will increase the end play). 7. After proper end play is obtained, remove the cover from the case and remove the idler shaft assembly from the transmission case. Maintenance Manual MM5.2 Copyright 2003 Issued AxleTech International Page 5

12 Section 4 Assembly Assemble Low Speed Driven Gear 1. Apply gear oil to the bronze bushing bore in the low speed driven gear and to the mating journal of clutch adapter. Install driven gear on the clutch adapter with clutch teeth of driven gear adjacent to the teeth of the clutch adapter. 2. Apply a film of oil to the driven gear oil seal journal. 3. Assemble the driven gear and clutch adapter to the hypoid pinion spline. NOTE: Due to the slight helix angle of the hypoid pinion spline, it will be necessary to drive the clutch adapter on the spline overcoming the interference fit. 4. Apply a bead of thread locking agent Loctite 277 or equivalent to the internal thread of the adapter nut. Install adapter nut and tighten to lb-ft ( N m). T 5. Check the end play of the low speed driven gear using dial indicator or feeler gage. Total movement of the gear should be within inch ( mm). Assemble Shift Components 1. Install shift fork to shift shaft (if previously removed). Align set screw hole in fork with the 30 degree hole in shift shaft. See cross section view on page 1 for orientation of fork. Install set screw into fork engaging the 30-degree hole in the shift shaft. Tighten to lb-ft (94-99 N m). Install soft iron lock wire through hole in set screw wrapping around fork and twist tight. T 2. Assemble the three detent springs and balls into the clutch adapter (balls are outboard of the springs see cross section view on page 1). Apply grease to assist in retaining the balls until the sliding clutch collar is installed. 3. Assemble the sliding clutch collar into the shift fork with the longer tapered portion of the collar facing the rear of the shift shaft (long tapered end will engage the clutch teeth of the low speed driven gear). 4. Assemble the sliding clutch collar and fork subassembly to the clutch adapter compressing the three detent balls and springs while the rear end of the shift shaft enters the shaft bore in the transmission case. Clutch collar should be in high position (sliding collar teeth are not engaging the clutch teeth of the low speed driven gear). Idler, Cover and Input Pinion Assembly 1. Drive the 2 case-to-cover dowels to extend out of the case approximately 50% of the length. This is to provide proper alignment of the cover and the gasket. 2. Install idler shaft assembly (idler shaft, idler gear, key, front and rear bearing cones) into the transmission case with idler shaft teeth mating with low speed driven gear teeth. 3. Apply a light film of non-hardening sealant to the transmission case flange. Install the case-to-cover gasket. 4. Apply a light film of non-hardening sealant to the transmission cover flange. Install the cover with shift shaft sliding through the shaft hole in the cover while aligning the cover dowel holes over the dowels. Lightly tap on the cover to get engagement of the dowels started, then use the case to cover bolts to seat the cover. 5. Install the case-to-cover capscrews, lock washers and nuts. Tighten nuts to lb-ft (54-68 N m). T 6. Apply a inch (3.18 mm) diameter bead of liquid gasket around the mounting flange face of the hydraulic motor adapter. 7. Install the hydraulic motor adapter and input drive pinion sub-assembly into the transmission cover. The drive pinion teeth must engage the idler gear teeth. If the sliding clutch collar is in the high position, the drive pinion teeth must engage the sliding collar teeth also. 8. Install lock washers and nuts on the motor adapter mounting studs. Tighten the nuts to lb-ft ( N m). T 9. If original shift shaft oil seal was removed, install a new seal using a sleeve that will fit over the shift shaft and properly contact the seal case. 10. Verify transmission will shift into high and low. Insert a temporary rod into the 0.39-inch (9.9 mm) diameter hole in outer end of shift shaft to allow pull/push force on the shift shaft (approximately 100 lb (445 N) force may be necessary). It may be necessary to rotate the hypoid ring gear or the input pinion slightly to allow movement of the sliding clutch collar. 11. Install shift shaft detent ball, spring, lock washer and screw. Tighten screw to lb-ft (27-34 N m). T NOTE: This detent purpose is to hold the transmission in neutral position. Copyright 2003 Maintenance Manual MM5.2 Page 6 AxleTech International Issued 10-03

13 Section 4 Assembly 12. Assemble hydraulic motor or motor and brake assembly to the transmission before filling with gear oil. Add oil until it runs out of bottom of level plug hole on side of transmission cover. 13. Attach the shift lever linkage. 14. Install the transmission support capscrews into the two inch 11 UNC threaded holes in top of cover. Tighten per OEM specification. Oil Specifications Oil capacity estimated = 8.0 pints (3.8 liters) for T-276 transmissions. CAUTION Oil MUST be filled separately from axle. T-276 Lube Recommendation 5 6 Oil Description A.P.I. Specification SAE Grade Outside Temperature Petroleum GL-1 Oil with Rust and Oxidation Inhibitor a A.P.I. GL-1 90W 80W Above 10 F ( 12 C) Above 15 F ( 26 C) 4 Heavy Duty Engine Oil a A.P.I.-CD, CE, SF, SG, or equivalent 50W 40W 30W Above 10 F ( 12 C) Above 10 F ( 12 C) Above 12 F ( 26 C) a a 90W GL-1 or 50W motor oil is same viscosity and commonly used above 10 F ( 12 C). Oil Change Intervals T-276 Torque Specs Item Description Size Lb-Ft N m 1 Case Differential Carrier 2 Idler Bearing Cover Capscrew 9/ / / 224 7/ /75 81/102 3 Case to Cover Bolt 3/ /50 54/68 4 Clutch Adapter Nut 1-1/ Input Adapter Mounting Nut 400/ / 678 1/ / / Shift Fork Set Screw 7/ /73 94/99 Items Not Shown in Section View: Shift Detent Spring Screw 1/ /25 27/34 Oil Level and Drain Plugs 1/ /35 34/47 Pipe Initial Change Check Level Change Oil 100 Operating Hours 250 Operating Hours 1,500 Operating Hours or twice per year (whichever comes first) NOTE: Severe operating conditions may require more frequent intervals. Maintenance Manual MM5.2 Copyright 2003 Issued AxleTech International Page 7

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16 Suite West Big Beaver Road Troy, Michigan U.S.A. Toll Free: Non-Toll Free: FAX: Website: AxleTech, International France 4, Rue Jean Servanton Boite Postale Saint Etienne Cedex 1 France (33) FAX: (33) AxleTech do Brasil Sistemas Automotivos Ltda. Avendia Joao Batista, 830 Centro-Osasco-SP Brasil Phone: FAX: MM5.2 Issued Copyright AxleTech International Printed in the USA