Central gear RBP835

Remove & Install

PT UNITED TRACTORS Tbk - SITE ADARO

2006
Contents

Contents
General Cleanliness................................................................ 3
Safety........................................................................ 3
Exploded view drawing, input shaft and bogie
differential ................................................................ 4
Exploded view drawing, pinion and axle
differential ................................................................ 6
Setting press force .................................................... 8
Oil............................................................................. 9

Spot repairs Cleaning the strainer unit ....................................... 10

Renewing the oil filter ............................................ 11
Renewing or sealing the oil pump .......................... 12
Oil or air leakage in the bogie differential
operation unit.......................................................... 14
Renewing sealing rings on input shaft.................... 16
Renewing sealing rings and bearings on output
shaft ........................................................................ 20

Overhaul Removing and fitting the central gear .................... 24

Overhaul of axle differential housing..................... 31
Removing the front cover and the input shaft ........ 36
Overhaul of pinion.................................................. 38
Removing the pinion and renewing the large
pinion bearing......................................................... 42
Removing bearing races in the gear housing.......... 44
Adjusting pinion height .......................................... 45
Fitting bearing races in the gear housing................ 46
Adjusting pinion bearing preload ........................... 48
Adjusting backlash and bearing preload ................ 50
Checking mesh image ............................................ 54
Axle differential lock operation unit ...................... 58
Overhaul of input shaft with bogie differential ...... 62
Fitting the input shaft and adjusting the bogie
differential lock ...................................................... 68
Renewing bearing races in the front cover and
adjusting the position of the input shaft bearing
race ......................................................................... 70
Fitting the front cover and setting the input shaft
bearing preload ....................................................... 72
Fitting the nut on the pinion ................................... 76
Specifications ......................................................... 77

© Scania CV AB 2005, Sweden

2 08:05-02
 General

General

The work description applies to two central

gears, RBP735 and RBP835. The difference
between the central gears is that some RBP835
parts have larger dimensions.

Cleanliness
Cleanliness is extremely important when
working with central gears. Contamination
reduces their service life considerably. Always
clean the outside of the central gear housing and
rear axle housing before removing the central
gear. Before reassembling the central gear, all
parts, old as well as new, should be cleaned.

Safety

! WARNING!

Never work under a vehicle with air

suspension, which is not fully secured
against falling, in case there is a change
of pressure in the air bellows. There is a
risk of getting trapped and injured.
Both the chassis and moving axle
suspension components must be
secured against falling with stands to
ensure absolute safety when working
under a vehicle.

© Scania CV AB 2005, Sweden

08:05-02 3
Exploded view drawing, input shaft and bogie differential

Exploded view drawing, input shaft and bogie

differential

© Scania CV AB 2005, Sweden

4 08:05-02
 Exploded view drawing, input shaft and bogie differential

1 Lock nut 42 Differential housing

2 End yoke 43 Bearing
3 Dust cover 44 Oil collector
4 Sealing ring 45 O-ring
5 Sealing seat 46 Differential gear (rear)
6 Screw 47 Bearing
7 Washer 48 Oil collector
8 Shim 49 Output shaft
9 Cover 50 Gear housing
10 Screw 51 Flange nut
11 Oil pump 52 Stud
12 Screw and washer 53 Strainer unit
13 Pump housing 54 Gasket
14 Screw 55 O-ring
15 Washer 56 Bearing
16 Front cover 57 Washer
17 Spacing washer 58 Retaining ring
18 Bearing 59 Sealing ring
19 Shift sleeve 60 End yoke
20 Fork 61 Lock nut
21 Fork pin 62 Conical gear set
22 Locking screw
23 Pull rod
24 Shim
25 O-ring
26 Cylinder
27 O-ring
28 Sealing ring
29 O-ring
30 Piston
31 Nut
32 Compression spring
33 Cover
34 Screw
35 Washer
36 Screw
37 Switch
38 Input shaft
39 Wear ring
40 Bushing
41 Differential gear (front)

© Scania CV AB 2005, Sweden

08:05-02 5
Exploded view drawing, conical gear set and axle differential

Exploded view drawing, conical gear set and axle

differential

© Scania CV AB 2005, Sweden

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 Exploded view drawing, conical gear set and axle differential

1 Half shaft 42 Screw

2 Shift sleeve 43 Screw
3 Adjusting ring 44 Switch
4 Bearing 45 Cover
5 Crown wheel 46 Compression spring
6 Screw 47 O-ring
7 Differential housing half (right) 48 Nut
8 Wear washer 49 Washer
9 Differential gear 50 Piston
10 Differential spider 51 Pull rod
11 Differential pinion 52 Sealing ring
12 Wear washer 53 O-ring
13 Differential housing half (left) 54 Cylinder
14 Screw 55 Shim
15 Bearing 56 O-ring
16 Oil collector 57 Lever
17 Adjusting ring 58 Fork pin
18 Pinion 59 Bracket
19 Bearing 60 Shaft
20 Shim 61 Internal hexagon bolt
21 Screw
22 Screw
23 Cap
24 Cap
25 Set screw
26 Gear housing
27 Nut
28 Stud
29 Adjusting ring
30 Shim
31 Bearing
32 Gear
33 Bearing
34 Nut
35 Front cover
36 Washer
37 Screw
38 Type plate
39 Protection cover
40 Threaded pipe
41 Oil filter

© Scania CV AB 2005, Sweden

08:05-02 7
Setting press force

Setting press force

The press force attained depends directly on the

hydraulic pressure from the air operated pump
99 004. The hydraulic pressure delivered by the
pump depends on the input air pressure, which
is governed by a pressure regulator.
The air pressure can be changed with a knob.
Pull the red locking ring towards the knob and
set the desired pressure which can be read on the
manometer.
A chart on the pump housing specifies the
desired press force from the hydraulic cylinder
as a function of the air pressure input to the
pump. The chart is shown below. 1 Compressed air connection.
2 Manometer.
3 Adjusting knob for air pressure.
4 Pump housing chart.

Set the press force to 120 kN (12 tons) as

follows:
1 Follow the press force axis (the bottom axis)
to the right until you reach 120 kN.
2 Then follow the line straight up until it cuts
the bold diagonal line. Draw a horizontal
line to the left from this intersection. This
gives a value of 5.2 bars, which is the
pressure required for 120 kN press force.

© Scania CV AB 2005, Sweden

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 Oil

Oil
The oil circulates between Hub reduction gears
RH735/835 and Central gear RBP735/835. The
oil level in the central gear and hub reduction
gears may therefore vary depending on how the
vehicle has been driven before it was brought
into the workshop. See the function description
for the central gear in the Workshop Manual,
main group 8.

! WARNING!

Use protective goggles when draining oil

from the central gear and hub reduction
gears. Oil can spray out at high
pressure.

Help protect our environment. Dispose of excess

oil in accordance with workshop procedures and
local regulations.

© Scania CV AB 2005, Sweden

08:05-02 9
Cleaning the strainer unit

Spot repairs

Cleaning the strainer unit

1 Clean the strainer unit.

2 Fit a new gasket.
3 Fit a new oiled O-ring.

4 Tighten the strainer unit to 180 Nm.

© Scania CV AB 2005, Sweden

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 Renewing the oil filter

Renewing the oil filter

1 Remove the oil filter.

2 Clean the oil filter contact surface on the oil
filter bracket .
3 Lubricate the new oil filter rubber sealing
with oil. Screw in the filter on the bracket
until the rubber sealing comes into contact
with the housing, and then screw one
additional half turn by hand.

© Scania CV AB 2005, Sweden

08:05-02 11
Renewing or sealing the oil pump

Renewing or sealing the oil pump

Removal

© Scania CV AB 2005, Sweden

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 Renewing or sealing the oil pump

Fitting

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08:05-02 13
Oil or air leakage in the bogie differential operation unit

Oil or air leakage in the bogie differential operation unit

General

Sealing agent 816 064

Grease 319 308
Locking compound 561 029

Dismantling
1 Remove screws 1.

! WARNING!

Hold the cover 2 when the screws 3 are

removed. The cover is spring loaded.
Tap the cover so that the sealing agent
releases.

2 Remove the screws, cover, compression

spring and O-ring.
3 The nut 4 is secured with locking
compound. Heat it to around 100°C before it
is carefully removed. Leave the nut threaded
on a few turns.
4 Blow air through hole A into the cylinder so
that the piston is forced out. Remove the nut
and piston.
5 Remove the cylinder from the gear housing.
Keep the shim(s).

© Scania CV AB 2005, Sweden

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 Oil or air leakage in the bogie differential operation unit

Assembly
1 Clean the parts carefully.
2 Fit a new sealing ring, the shim or shims, a
new oiled O-ring and fit the cylinder.
3 Fit a new greased O-ring on the piston and
fit the piston.
4 Apply locking compound to the thread,
screw on the nut, and tighten to 20 Nm.
5 Fit a new O-ring in the air duct, fit the
spring, apply sealing agent to the cover (be
careful around the screw holes) and tighten.
6 Check the function of the switch. The circuit
should be closed when the differential lock
is engaged.

© Scania CV AB 2005, Sweden

08:05-02 15
Renewing sealing rings on input shaft

Renewing sealing rings on input shaft

Tools

Number Designation Illustration Tool board

88 292 Pull rod 88 292 G2

00 1848
98 257 Support drift 98 257
G2, AM2

110 076
98 568 Support drift 98 568
R2

00_1618

98 765 Splined socket 98 765

00_1642

G2

99 001 Adapter 99 001 H1

00 1562

99 003 Hydraulic cylinder H1

99 004 Hydraulic pump H1

99 005-1 Pusher adapter 99 005−1

G1, H1
111 423

99 010 Plain bushing H1

99 011 Threaded bushing 99 011 H1

00 1565

© Scania CV AB 2005, Sweden

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 Renewing sealing rings on input shaft

Number Designation Illustration Tool board

99 012 Threaded spindle 99 012
H1

109 431
99 040 Pusher adapter 99 040
H1

110 995
99 124 Puller 99 124 G1, H1

110 253
99 129 Counterhold 99 129 G2

00_1616
99 377 Drift 99 377
R3
112 705

587 318 Puller XA3

114 693

587 319 Puller XA3

© Scania CV AB 2005, Sweden

08:05-02 17
Renewing sealing rings on input shaft

Dismantling

Figure 2:
• Remove the end yoke using the tools as
illustrated.

Figure 3:
• The sealing can separate into two parts. One
part is mounted on the end yoke and the
other in the sealing seat.
• Remove the part in the sealing seat
carefully. Make sure the surface in the
sealing seat is not damaged.
• Carefully remove the dust cover and the
sealing part which is fitted on the end yoke.
Use the tools as illustrated. Make sure the
surface of the end yoke is not damaged.

© Scania CV AB 2005, Sweden

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 Renewing sealing rings on input shaft

Assembly

Figure 1:
• Renew the dust cover if it is damaged.
• Press on the new sealing ring.
Figure 2:
• Press on the end yoke with the tool as shown
in the picture. Complete with a press force
of 100 kN. Refer to Setting press force.

IMPORTANT! Never strike the end yoke. Risk

of bearing damage.

Figure 3:
Fit a new nut and tighten as indicated in
alternative 1 or 2.
• Alternative 1: Torque tighten the nut to
1000 Nm.
• Alternative 2: Torque tighten the nut to
300 Nm. Mark the sleeve and end yoke as
illustrated and tighten a further 26 mm to
reach 1000 Nm.
Figure 4:
• Lock the nut by staking it into both recesses
in the end yoke.

© Scania CV AB 2005, Sweden

08:05-02 19
Renewing sealing rings and bearings on output shaft

Renewing sealing rings and bearings on output shaft

Tools

Number Designation Illustration Tool board

87 445 Press drift 87 445 AD2

00_1609
87 596 Slide hammer 87 596 D2

00 1610
98 332 Support drift R1

98 765 Splined socket 98 765 G2

00_1642

99 003 Hydraulic cylinder H1

99 004 Hydraulic pump H1

99 005-1 Pusher adapter 99 005−1

G1, H1
111 423

99 005-4 Pusher adapter H1

99 010 Plain bushing H1

99 012 Threaded spindle 99 012

H1
109 431

© Scania CV AB 2005, Sweden

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 Renewing sealing rings and bearings on output shaft

Number Designation Illustration Tool board

99 040 Pusher adapter 99 040
H1

110 995
99 147 Drift R3

99 413 Drift R3

99 471 Adapter R3

587 320 Puller XA3

© Scania CV AB 2005, Sweden

08:05-02 21
Renewing sealing rings and bearings on output shaft

Dismantling
• Remove the end yoke. Where necessary, use
the same tools as for the input shaft. Refer to
Spot repairs: Renewing input shaft sealing.
• Dismantle as shown in detail pictures 1-5.

© Scania CV AB 2005, Sweden

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 Renewing sealing rings and bearings on output shaft

Assembly

Illustration Comments on the illustrations

1 Press the bearing onto the shaft using the tool as illustrated.
2 Screw on the adapter and insert the shaft in the rear axle housing. Ensure
that the shaft splines engage with the splines in the rear differential gear.
3 Fit 99 147 on adapter 99 471 and tap in the bearing and the shaft.
5 Press in the sealing ring using drift 99 413 by screwing the nut using
splined socket 98 765.

• Fit the end yoke. Refer to Spot repairs:

Renewing input shaft sealing.
• Fit a new nut, tighten to 400 Nm and lock it
by upsetting it in the two recesses in the end
yoke.

© Scania CV AB 2005, Sweden

08:05-02 23
 Central Gear

Overhaul

Remove and Install

Specifications

General Part No.

Sealing agent 816 064

Tools

Number Designation Illustration Tool board

98 402 Holder for fixture shaft F1

98 403 Fixture shaft F1

00 1644

98 403

98 404 End yoke bracket 98 404 F1

114 965

98 405 Bracket and fixture beam F1

19
 Central Gear

102 90
Number Designation Illustration Tool board
99 469 Fixture beam F2

98 776 Fixture 98 776 A

110 877
99 167 Lifting yoke 99 167 G1

00 1625
587 313 Jack

under a raised vehicle.

• Take the load off the axle housing before

removing the central gear.
• Vehicles with leaf spring suspension must
be supported under the frame or springs as
illustrated.

20
Removing and fitting the central gear

Removal

! WARNING!

Never work under a vehicle with air

suspension, which is not fully secured
against falling, in case there is a change
of pressure in the air bellows. There is a
risk of getting trapped and injured.
Both the chassis and moving axle
suspension components must be
secured against falling with stands to
ensure absolute safety when working
under a raised vehicle.

• Take the load off the axle housing before

removing the central gear.
• Vehicles with leaf spring suspension must
be supported under the frame or springs as
illustrated.

! WARNING!

Use protective goggles when draining

oil. Oil can spray out at high pressure if
the rear axle housing ventilation is
blocked.

1 Drain the oil from the axle housing (also

refer to the oil section).
2 Drain the oil from the hub reduction gears
and pull out the half shafts as instructed in
the work description for Hub reduction gear
RH735/835 under main group 9.

© Scania CV AB 2005, Sweden

26 08:05-02
 Removing and fitting the central gear

3 Disconnect the electrical wiring and

compressed air lines to the differential lock.
4 Remove the propeller shaft.
5 Remove obstructing brake components as
instructed in the work description under
main group 10.
6 Undo all nuts except two (one in each upper
corner), retaining the central gear.
7 If necessary, clean the threads in the puller
hole using a pilot tap and screw in a 60 mm
fully threaded M10 bolt.
8 Attach the central gear to the jack using the
tool as illustrated.

9 Remove the two remaining nuts securing the

central gear and pull it out from the rear axle
housing using the jack and the puller bolt.

!
Be careful during this procedure. Do not
stand at the side of the gear. Risk of
crush injuries if it tips over.

© Scania CV AB 2005, Sweden

08:05-02 27
Removing and fitting the central gear

Fitting
1 Clean the axle housing internally and the
contact surface to the axle gear. Torque
tighten the oil drain plug to 100 Nm.
2 Fit a new filter.
3 Check position of oil pipes and their
attachment to the rear axle housing.
4 Make sure all the studs are secure in the rear
axle housing. Loose studs must be removed
and fitted with thread seal
(Part No. 561 019) on the threads. Torque
tighten the studs to 80 Nm.
5 Apply a bead of silicone rubber around the
contact surfaces and around each stud as
illustrated.

© Scania CV AB 2005, Sweden

28 08:05-02
 Removing and fitting the central gear

6 Assemble the jack and the fixture parts as

illustrated. Align the central gear on the jack
fixture. Tighten the end yoke in the end
yoke bracket.

! WARNING!

Be careful during this procedure. Do not

stand at the side of the gear. Risk of
crush injuries if it tips over.

7 Place the central gear in position in the axle

housing.
8 Fit every second nut and tighten the nuts
diagonally by hand. Pull in the central gear
with the axle housing surface and gear
housing surface in parallel.

Note: The central gear must not be forced into

place. If there is resistance then the cause must
be investigated.

9 Fit the remaining nuts. Tighten the nuts to

300 Nm.

© Scania CV AB 2005, Sweden

08:05-02 29
Removing and fitting the central gear

10 Connect the electrical wiring and

compressed air lines to the differential
locks.
11 Fit brake components that were removed as
instructed in the work description under
main group 10.
12 Push in the half shafts and refit the hub
reduction gear components as described in
the work description for RH735/835, main
group 9.
13 Fill rear axle housing with oil up to lower
edge of level plug.
14 Fill hub reduction gears with oil. Refer to
work description for hub reduction gears in
the Workshop Manual, main group 9.
For the correct fluid grade, see Workshop
Manual - Oils, fluids and lubricants, in main
group 0.

© Scania CV AB 2005, Sweden

30 08:05-02
 Overhaul of axle differential housing

Overhaul of axle differential housing

Tools

Number Designation Illustration Tool board

98 524 Drift 98 524
R1

110 454
98 566 Drift 98 566 R1

00 1617

98 568 Support drift 98 568 R2

00_1618

99 092 Drift 99 092 AD2

00 1619

587 428 Puller XA3

114 056

587 432 Puller plate XA3

114 693

© Scania CV AB 2005, Sweden

08:05-02 31
Overhaul of axle differential housing

Dismantling

Illustration Comments on the illustrations

1 Mark the caps and the housing on RBP735. Remove the caps.
Note: The outer and the inner races for the two bearings on
RBP735 must be each kept together if they are to be reused.
Remove the coupling half and the operation units for the axle
differential lock.
Lift out the differential housing.
2 Tension the puller plate so that it grips well.
3 Turn a notch at A, similar to the one at B on 98 568 when
working with RBP835.
Tension the puller plate so that it grips well.
4 If necessary, clamp the housing in the press and undo the bolts
with a long tommy bar.
5 Mark the differential housing halves together with the
differential spider (A).
Before separating the differential housing halves, note that the
component parts of the differential housing must be refitted in
their original location during assembly.
6 Keep parts 8-12 together if they are to be reused. If any of the
wear washers needs to be renewed, both washers at pos. 8 and all
four washers at pos. 12 must be renewed, respectively.

© Scania CV AB 2005, Sweden

32 08:05-02
 Overhaul of axle differential housing

© Scania CV AB 2005, Sweden

08:05-02 33
Overhaul of axle differential housing

Assembly

IMPORTANT! All parts must be cleaned

thoroughly before assembly.

Figure 1:
• Reassemble the component parts of the
differential housing according to the marks
made earlier. Oil all components thoroughly.
• Clamp the differential housing in a press
and tighten the bolts diagonally to 40 Nm
and then tighten diagonally a further 30°
(half a hexagon).
Figure 2:
• Turn the differential housing over in the
press and fit the crown wheel. Fit new bolts
with pre-applied locking compound.
Tighten the bolts diagonally to 170 Nm and
then diagonally a further 60° (a hexagon).
This work must be carried out without
interruption since the locking compound is
activated by the heat generated by friction in
the thread.

© Scania CV AB 2005, Sweden

34 08:05-02
 Overhaul of axle differential housing

! WARNING!

Use protective goggles when pressing

as oil may spray up.

Figures 3 and 4:
• Oil the sliding surfaces and press on the
bearing using the tool as shown in the
picture. Begin with the crown wheel side.
Check that the bearings are pressed to the
bottom.

© Scania CV AB 2005, Sweden

08:05-02 35
Removing the front cover and the input shaft

Removing the front cover and the input shaft

Remove the end yoke and oil pump as described

under Spot repairs. Remove the protection cover
and oil filter.

Illustration Comments on the illustrations

1 Loosen all bolts and remove all except two.
2 Turn the central gear in the stand and tap the
lugs nearest to the guide pins. Turn the gear
housing around again, remove the bolts and
lift away the front cover.
3 The locking screw is secured in position using
locking compound. Heat it to around 100°C
and remove.
4 Remove the operation unit and fork.
5 Lift out the input shaft and remove the
differential gear.
The shaft must be lifted under the gear and at
the same time angled out from the gear on the
pinion.

© Scania CV AB 2005, Sweden

36 08:05-02
 Removing the front cover and the input shaft

© Scania CV AB 2005, Sweden

08:05-02 37
Overhaul of pinion

Overhaul of pinion

Tools

Number Designation Illustration Tool board

87 247 Drift 87 247 R1

107 759
87 550 Drift AD2

98 332 Support drift 98 332 R1

110 119

98 364 Assembly drift R1

98 450 Shank AM1, AD/AS2,

R2
00 1633

98 450

98 566 Drift 98 566 R1

00 1617

© Scania CV AB 2005, Sweden

38 08:05-02
 Overhaul of pinion

Number Designation Illustration Tool board

98 575 Support drift 98 575 G2

00 1621
98 616 Adjustable drift 98 616
AD2, R2

110 806
99 003 Hydraulic cylinder H1

99 004 Hydraulic pump H1

99 005-1 Pusher adapter 99 005−1

H1
111 423

99 005-4 Pusher adapter H1

99 010 Plain bushing H1

99 012 Threaded spindle 99 012 H1

109 431

© Scania CV AB 2005, Sweden

08:05-02 39
Overhaul of pinion

Number Designation Illustration Tool board

99 040 Pusher adapter 99 040 H1

110 995
99 092 Drift 99 092 AD2

00 1619
99 147 Drift R3

99 192 Drift 99 192 G4

00 1639

99 253 Drift R2

99 276 Setting ring R3

99 512 Dummy bearing R3

99 335 Pressplate 99 335 AD4

00 1883

© Scania CV AB 2005, Sweden

40 08:05-02
 Overhaul of pinion

Number Designation Illustration Tool board

99 458 Pinion position template R3

99 459 Pinion position template R3

99 473 Setting ring R3

99 474 Dummy bearing R3

587 315 Puller XA3

587 697 Splined socket R3

© Scania CV AB 2005, Sweden

08:05-02 41
Removing the pinion and renewing the large pinion bearing

Removing the pinion and renewing the large pinion

bearing

IMPORTANT! There is a very high risk of the

central gear housing being damaged if the
pinion is pressed out and is allowed to drop
freely onto the press table.

Illustration Comments on the illustrations

2 Let the pinion drop down onto a wooden board
50-55 mm thick. Remove bearing and gear and
lift off the gear housing.
Keep the adjusting ring and the shims.
3 Cut off the pinion bearing roller cage and grind
a groove in the bearing race using a grinding
wheel with a diameter of less than 60 mm. Make
sure the pinion is not damaged.
4 Weld a few beads on the bearing race with an
electric welder. Protect the pinion from welding
spatter by using, for example, a rag. Cool using
a wet rag after each weld bead. The bearing race
will break through shrinkage after 4-5 welds.
5 and 6 Press on the pinion bearing.

© Scania CV AB 2005, Sweden

42 08:05-02
 Removing the pinion and renewing the large pinion bearing

© Scania CV AB 2005, Sweden

08:05-02 43
Removing bearing races in the gear housing

Removing bearing races in the gear housing

Figure 1:
• Cut four notches in the oil collector and
bend up the tabs, as shown in the detail
picture, to provide space for the puller arms.
Draw out the bearing race.

© Scania CV AB 2005, Sweden

44 08:05-02
 Adjusting pinion height

Setting the pinion height

Figure 1:

• Fit the shims that were used earlier under

the bearing race.
• Lubricate the running surface of the setting
ring and fit it instead of the bearing race.
• Fit the pinion and rotate it a few turns.
Figure 2:
• A = Two-digit deviation measurement in
hundredths of a mm which is always
positive (B = parallel operation number
which is also stamped on the end of the
pinion).
• The pinion setting dimension is (A + 0.5)
+/-0.05.
Figure 3:
• Position the pinion position template
vertically and parallel to the differential
centre-line.
• Measure the setting dimension of the pinion
as illustrated.
• Example: The number 37 is on the crown
wheel. This will give a setting dimension of
0.37 +0.5 = 0.87. The distance between the
end face of the pinion and the pinion
position template must therefore be
0.82-0.92 mm.
• Adjust if necessary by changing shims.
Shims are available in thicknesses 0.25, 0.30
and 0.40.

© Scania CV AB 2005, Sweden

08:05-02 45
Fitting bearing races in the gear housing

Fitting bearing races in the gear housing

Illustration Comments on the illustrations

1 Fit the oil collector turned as shown in the
picture. Lubricate the sliding surfaces and
press on the input shaft bearing race.
2 and 3 Lubricate the sliding surfaces and press on the
pinion cylindrical bearing race.
4 and 5 Fit shims according to the calculated values
from the pinion height setting. Lubricate the
sliding surfaces and press on the bearing race
for the large pinion bearing.
Check carefully when working on RBP835 that
tool 98 332 does not come into contact with the
gear housing.

Check pinion height:

• Move the gear housing to a stand.
• Fit the pinion and rotate it a few turns.
• Check that the set pinion height has not
changed.

© Scania CV AB 2005, Sweden

46 08:05-02
 Fitting bearing races in the gear housing

© Scania CV AB 2005, Sweden

08:05-02 47
Adjusting pinion bearing preload

Adjusting pinion bearing preload

Note: Start by turning the gear housing on the

stand so that the pinion shaft is leaning
downwards.

Illustration Comments on the illustrations

1 Slip on adjusting ring 29, shims 30 (which previously
were under the outer bearing) and the dummy bearing.
Screw 99 040 onto the pinion and fit the other tools as
illustrated. Set the press force to 120 kN. Rotate the
pinion to and fro while pressing so that the bearing rollers
take their correct positions.
2 Using a spring balance, check that the bearing preload is
7-12 Nm (20-35 N on the spring balance) for new
bearings and 3-4 Nm (9-12 N on the spring balance) for
used bearings. Adjust where necessary by replacing
adjusting ring or shims.
Adjusting rings are available in the following thicknesses:
6.74, 6.76, 6.78, 6.80 and 6.82 mm
Shims are available in the following thicknesses: 0.25,
0.30, 0.40 and 0.50 mm.
Replace the dummy bearing with the pinion bearing when
the bearing preload is correct. Check the preload before
removing the tools.
3 Press on the gear.
4 Press on the cylindrical bearing and turn the nut by hand.

© Scania CV AB 2005, Sweden

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 Adjusting pinion bearing preload

© Scania CV AB 2005, Sweden

08:05-02 49
Adjusting backlash and bearing preload

Adjusting backlash and bearing preload

Backlash:
RBP735
• Gear ratio 3.67: 0.25-0.33 mm
• Gear ratio 3.93 and 4.22: 0.20-0.28 mm
RBP835
• Gear ratio 3.96 and 5.14: 0.30-0.41 mm
• Gear ratio 4.27 and 4.85: 0.25-0.33 mm

Tools

Number Designation Illustration Tool board

98 075 Dial gauge 98 075 D2
0
90 10
10 90

80 20
20
80

15 5
30 10
70
70 30

40 60
60 50 40
50
00_1637

587 250 Indicator stand

102350

Fitting the differential housing

1 Lift the differential housing together with

the two outer bearing races for each
respective bearing.
2 Position the two caps in place. One of the
caps has a groove which must be fitted in
the corresponding groove in the housing.

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 Adjusting backlash and bearing preload

Adjusting backlash and bearing preload

1 Loosely tighten the cap bolts. The bolt

threads and contact surfaces must be
lubricated.

2 Oil the threads of the two adjusting rings.

3 Fit the oil collector and screw in both
adjusting rings so that the races are loosely
resting against the bearings.
4 Then screw in adjusting ring A until there is
no backlash (if necessary, gradually undo
the adjusting screw on the other side).
Unscrew the adjusting ring A one turn.

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Adjusting backlash and bearing preload

5 Fit indicator stand with dial gauge 587 250

as illustrated.

6 Screw in the adjusting ring on the other side

B until at least 0.50 mm backlash is
obtained.
7 Unscrew the adjusting ring A one turn.
8 Screw in the adjusting ring A until the
clearance is within the specified tolerance. It
is better to be closer to the lower value,
because the clearance can increase slightly
when the cap bolts are tightened. Screw in
the set screw so that the tapered point on the
set screw contacts the lugs of the adjusting
ring. Then undo the set screw slightly.
Tighten the adjusting ring on the other side
B by hand until it starts to feel tight. Then
tighten another 2-3 notches. Screw in the set
screw so that the tapered point on the set
screw contacts the lugs of the adjusting ring.
Then undo the set screw slightly.

Note: Only screw the adjusting ring A inwards.

If the clearance is less than the lowest value, it is
necessary to start again from step 6 before the
clearance can be reduced again.

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 Adjusting backlash and bearing preload

9 Move the stand with the dial gauge to one

side. Rotate the crown wheel 5-6 turns and
check the backlash. Turn the stand back and
check the backlash.

10 Tighten both cap bolts to 120 Nm.

11 Check that the backlash is still within the
specified values. If the backlash is too great,
undo the cap bolts slightly. Unscrew the
adjusting ring B one half turn, and then
screw in the adjusting screw A until the
backlash is correct again. Screw in the set
screw as described in step 8. Then screw in
the adjusting ring B by hand until it starts to
feel tight, and then a further 2-3 notches.
Screw in the set screw as described in step 8.
Then tighten the cap bolts again to 120 Nm
and check the backlash at four points. If the
clearance is less than the lowest value, it is
necessary to start again from step 6 before
the clearance can be reduced again.
12 Tighten the cap bolts a further 60°, then
check the backlash again and lock the
adjusting rings with the set screws.
Tightening torque 10 Nm.

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Checking mesh image

Checking mesh image

IMPORTANT! The mesh image confirms that

the teeth are correctly set. A poor mesh image
can lead to damage to the teeth and noise.

1 Apply a thin film of colour marker on two

adjacent crown wheel teeth. Turn the crown
wheel one half turn and repeat the
procedure.
2 Make sure the colour marker makes contact
with the pinion. Turn the end yoke to and fro
a few times. Brake the crownwheel with
your hand at the same time.
Figure 1:
• Check that the mesh image on the leading
and trailing flanks of the teeth corresponds
to the pictures.
• 1 = correct mesh image on leading flank of
crown wheel, convex side.
• 2 = correct mesh image on trailing flank of
crown wheel, concave side.
Figure 2:
• The mesh image should be in the centre of
the tooth flank when a vertical measurement
from the tooth is carried out. At the same
time the horizontal mesh image should not
be outside the marked areas.
• 1 = driving side
• 2 = trailing flank (brake side)
• A = top of tooth.

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 Checking mesh image

Correct mesh image

© Scania CV AB 2005, Sweden

08:05-02 55
Checking mesh image

Incorrect mesh image

1 Driving side
2 Trailing flank
The pinion must be adjusted further away from
the centre of the crown wheel (at the same time
the backlash must be retained by adjusting the
crown wheel inwards without changing the
bearing preload).

© Scania CV AB 2005, Sweden

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 Checking mesh image

Incorrect mesh image

1 Driving side
2 Trailing flank
The pinion must be adjusted closer to the centre
of the crown wheel (at the same time the
backlash must be retained by adjusting the
crown wheel outwards without changing the
bearing preload).

© Scania CV AB 2005, Sweden

08:05-02 57
Axle differential operation unit

Axle differential lock operation unit

Removal
1 Unscrew the internal hexagon bolts 1 and
remove the lever with bracket together with
the shift sleeve.
2 Remove the bolts 2 and pull the operation
unit out of the gear housing. Remove the
shims (one or more) and the O-ring.

© Scania CV AB 2005, Sweden

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 Axle differential operation unit

Dismantling

! WARNING!

Hold the cover 3 and the cylinder 4 when

the bolts 5 are removed. The parts can
fly off because of the spring force.

1 Remove the switch.

2 Undo the bolts 5, press the pull rod so that
the cover and cylinder separate.
3 Remove the bolts, spring and O-ring for the
air duct and press out the pull rod with
piston.
4 Fasten the pull rod in a screw vice with soft
jaws. The nut 6 is locked with locking
compound, so it should be heated to around
100°C before being carefully removed.
5 Remove the O-ring and sealing ring.

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08:05-02 59
Axle differential operation unit

Assembly and adjustment

1 Fit a new, greased O-ring onto the piston, fit

it on the pull rod, fit the washer, apply
locking compound to the thread and tighten
the nut to 20 Nm

2 Fit a new, oiled sealing ring in the cylinder,

insert the piston in the pull rod and fit a new
O-ring for the air duct.
3 Fit the spring and screw on the cover.
4 Fit the shim(s) which were removed during
the removal process, fit a new, oiled O-ring
and fit the operation unit in the gear
housing.
5 Position the lever fork pins in the coupling
sleeve and fasten the bracket with lever in
the gear housing with the screws.

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 Axle differential operation unit

6 Check the operation of the mechanism.

Connect compressed air to the cylinder and
check that the clearance between the
coupling halves is 0.1-0.6 mm. Adjust the
clearance using shims. Example: Removing
one 0.8 mm shim will increase the clearance
by approximately 0.5 mm. Shims are
available in thicknesses of 0.5, 0.8 and
2.5 mm.
7 Fit the switch. Torque tighten to 20 Nm.
8 Check the function of the switch. The circuit
should be closed when the differential lock
is engaged.

© Scania CV AB 2005, Sweden

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Overhaul of input shaft with bogie differential

Overhaul of input shaft with bogie differential

Tools

Number Designation Illustration Tool board

87 223 Drift 87 223 D3, AM2, B1

00 1627

87 443 Drift 87 443 AM1

110 320

87 569 Hollow drift PT1

98 364 Assembly drift R1

98 638 Assembly drift 98 638 G3

110 816

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 Overhaul of input shaft with bogie differential

Number Designation Illustration Tool board

99 135 Drift 99 135 R2

00 1852
99 190 Drift 99 190 G4

00 1638

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Overhaul of input shaft with bogie differential

Overhaul of input shaft

Illustration Comments on the illustrations

1 Place a piece of wood at the bottom of the hollow drift so that the
shaft is not damaged when it drops down onto the press table. Ensure
that the differential pinion and the differential gear teeth have
meshed before pressing.
2 Cut off the roller cage on the large bearing and grind a groove in the
bearing race using a grinding wheel with a diameter of less than
60 mm. Make sure the pinion is not damaged.
3 Weld a few beads on the bearing race with an electric welder. Protect
the shaft from welding spatter using for example a rag. Cool using a
wet rag after each weld bead. The bearing race will break through
shrinkage after 4-5 welds.
Scrape the shaft end clean removing any rust or paint. The shaft end
must be clean and undamaged, to enable correct measuring at later
stages.
4 Press on the large bearing.
5 Knock out the bushing using a drift or similar. Turn the differential
gear and press in a new bushing using 98 638.
6 Check the wear washer for damage and wear. The wear washer
should be renewed if the thickness is less than 8 mm.
Turn the shaft, fit the component parts and press on the small
bearing.

© Scania CV AB 2005, Sweden

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 Overhaul of input shaft with bogie differential

Input shaft

© Scania CV AB 2005, Sweden

08:05-02 65
Overhaul of input shaft with bogie differential

Overhaul of differential gear

Illustration Comments on the illustrations

1 A) O-ring
B) Oil collector
C) Bearing race
2 When the bearing race is tapped out, the oil collector is
distorted and must be replaced with a new one.
3
4 Cut off the bearing roller cage and grind a groove in the
bearing race using a grinding wheel with a diameter of less
than 60 mm. Ensure that the differential gear is not
damaged.
5 Weld a few beads on the bearing race with an electric
welder. Protect the differential gear from welding spatter
with for example a rag. Cool using a wet rag after each weld
bead. The bearing race will break through shrinkage after
4-5 welds.
6 Press on the bearing.
7 A) Fit a new oiled O-ring.
B) Position the oil collector, turned as shown in the picture.
C) Press on the bearing race.

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 Fitting the input shaft and adjusting the bogie differential

Rear differential gear

© Scania CV AB 2005, Sweden

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Fitting the input shaft and adjusting the bogie differential

Fitting the input shaft and adjusting the bogie

differential lock

For dismantling and assembly of the operation • Note the measured clearance for the side
unit, refer to Spot repairs. with the smallest measurement.
Figure 1: Setting the clearance between coupling
halves:
• Oil the component parts and lift the shaft
into place in the rear differential gear. • Correct clearance: 0.1-0.6 mm.
Figure 2: Example:
• Fit the fork. Oil the pull rod and fit the • Measured clearance: 3.20 mm.
operation unit without O-rings and shims.
• Gear movement: 1.55 mm.
Figure 3:
• 3.20 mm-1.55 mm = 1.65 mm.
• Bolt together the component parts.
• Try and obtain the lower value: 0.1 mm.
• Rotate the shaft a number of rotations in
both directions so that the bearing rollers • Suitable thickness of shims in this
move into the correct position. example: 1.50 mm.

The front differential gear can move axially on • 1.65 mm-1.50 mm gives 0.15 mm
the input shaft and due to the teeth cutting the clearance.
gear moves forwards when in operation
Figure 6:
(upwards in the picture). When adjusting the
differential lock this movement must be taken • Remove the operation unit, fit shims of the
into consideration. measured thickness and fit a new oiled
O-ring. Apply locking compound to the
Figure 4:
locking screw and screw it in place.
• The shaft end must be free from paint, rust
and damage. • Shims are available in the following
thicknesses: 0.5, 0.65, 0.8 and 2.5 mm.
• Fit the magnetic foot to the input shaft gear
and adjust the dial gauge to the shaft end.
Zero the dial gauge, hold the bearing (so
the shaft does not move upwards) and lift
the gear until it stops.
• Read and note the value on the dial gauge.
Figure 5:
• Connect compressed air to the operation
unit, and check the clearance between the
shift sleeve and the differential gear at the
fork pins on both sides using a feeler
gauge.

Note: The feeler gauge must be parallel with

the angle of the toothed coupling (see picture).

© Scania CV AB 2005, Sweden

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 Fitting the input shaft and adjusting the bogie differential

© Scania CV AB 2005, Sweden

08:05-02 69
Renewing bearing races in the front cover

Renewing bearing races in the front cover

Tools

Number Designation Illustration Tool board

99 127 Drift 99 127 AM1

00 1629
99 147 Drift R3

99 253 Drift R2

Illustration Comments on the illustrations

1 Remove the sealing seat and keep the shims.
2 If the input shaft bearing race is not to be renewed, it should be tapped
down using a brass drift so that it is at the same height as the inside of the
front cover.
3 Removing the input shaft bearing race.
4 Press in the input shaft bearing race until it protrudes 7 mm above the
cover edge (the bearing race moves into the correct position when the
sealing seat is screwed into place).
5 Remove the bearing race for the pinion cylindrical bearing.
6 Block up under the cover so it is level. Press in the bearing race for the
pinion cylindrical bearing.

© Scania CV AB 2005, Sweden

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 Renewing bearing races in the front cover

© Scania CV AB 2005, Sweden

08:05-02 71
Fitting the front cover and setting the input shaft bearing preload

Fitting the front cover and setting the input shaft bearing
preload

Tools

Number Designation Illustration Tool board

98 075 Dial gauge 98 075

0
90 10
10 90

80 20
20
80

15 5
30 10
70
70 30

40 60
60 50 40
50
00_1637

99 049 Claw spanner 99 049 AM1

111 417

99 192 Drift 99 192 G4

00_1639

99 253 Drift R2

587 250 Indicator stand

102350

587 697 Splined socket R3

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 Fitting the front cover and setting the input shaft bearing preload

Fitting the cover

Figure 1:
• Apply sealing agent to the front cover
contact surface. Be careful around the holes.

Figure 2:
• Lower the cover and fit the bearing race to
the pinion cylindrical bearing.
• Fit all bolts except the two which are
fastening bolts for the oil filter protection
cover.
• Tighten the bolts to 105 Nm.

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Fitting the front cover and setting the input shaft bearing preload

Adjusting bearing preload

Figure 1:
• Fit the sealing cover without shims and
tighten to 105 Nm. The bearing race is
pressed down towards the bearing.
• Fit the nut and turn the shaft a number of
rotations and at the same time press the
shaft downwards so that the bearing rollers
move into the correct position. Press the
shaft downwards and remove the nut.

Figure 2:
• Slip the two tools onto the shaft as shown in
the picture.
• Check that the shaft end and threads on the
shaft and in the nut are fault free. Oil the
thread and the nut contact surface against
99 253. Turn the nut until it approaches the
tool (the shaft must not move). The nut
must be easily turned.
• Fit the indicator stand to the front cover and
zero the dial gauge to the shaft end. Mark
the measurement point on the shaft.
Figure 3:
• Screw the nut using a claw spanner so that
the shaft is lifted up towards the front
bearing race. Turn the input shaft one to two
rotations so that the bearing rollers in the
front bearing move into the correct position.
• Note the reading.

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 Fitting the front cover and setting the input shaft bearing preload

Input shaft bearing preload 0.20 mm.

Adjusting bearing preload:
• Measure the axial clearance as described
previously. Place the corresponding
thickness of shims under the sealing seat
plus a further 0.20 mm.
Example:
• Axial clearance reading: 0.32 mm.
• Fit 0.50 mm shims.
• 0.50 mm - a clearance of 0.32 gives a
bearing preload of 0.18 mm.
• Shims are available in the following
thicknesses: 0.20, 0.25, 0.30 and 0.40 mm.
Fitting the sealing cover and the end yoke:
• Apply sealing agent to the sealing cover as
illustrated. Be careful around the screw
holes.
• Fit the spacing ring with the thinner part
turned towards the bearing.
• Fit the oil filter as described in the
description under Spot repairs. Fit the
protection cover for the oil filter and tighten
the sealing cover screws to 105 Nm.
• Fit the end yoke, screw on the nut and
tighten to 600 Nm. Refer to Spot repairs:
Renewing input shaft sealing.

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Fitting the nut on the pinion

Fitting the nut on the pinion

Tools

Number Designation Illustration Tool board

88 292 Pull rod 88 292 G2

00 1848
99 129 Counterhold 99 129 G2

00_1616

587 697 Splined socket R3

• Fit a new nut to the pinion, tighten to

1000 Nm. When tightening, the bogie
differential lock must be pressurised with
air.

IMPORTANT! The nut should be locked by

upsetting the collar at the two recesses in the
pinion shaft.

• Fit the oil pump as described in the

description under Spot repairs: Renewing or
sealing the oil pump.

© Scania CV AB 2005, Sweden

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 Specifications

Specifications

General

Oil volume RBP730 11.2 litres

Oil volume RBP835 12.0 litres
Oil volume, RH735 and RH835 2.0 litres
Oil type Refer to Group 0
Thread seal Part No. 561 019
Locking compound Part No. 561 029
Grease for compressed air components Part No. 319 308
Sealing agent (silicon rubber) Part No. 816 064
Sealing agent Part No. 584 079

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08:05-02 77
Specifications

Tightening torque

Differential housing bolts 40 Nm + 30°

Crown wheel bolts 170 Nm + 60°
Pinion nut 1000 Nm
Nut for input shaft end yoke 1000 Nm
Nut for output shaft end yoke 400 Nm
Bearing cap bolts 120 Nm + 60°
Locking screws for adjusting rings 10 Nm
Front cover bolts 105 Nm
Screws for sealing cover 105 Nm
Studs 80 Nm
Stud nuts 300 Nm
Oil plug 100 Nm
Switch 20 Nm
Oil pump bolts 10 Nm
Oil pump cover bolts 8 Nm
Nut, bogie differential piston 20 Nm
Nut, axle differential piston 20 Nm

© Scania CV AB 2005, Sweden

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 Specifications

Setting values

Pinion rolling resistance at a press force of 120 kN (new bearings) 7-12 Nm

Pinion rolling resistance, value on the spring balance (new bearings) 20-35 N
Pinion rolling resistance at a press force of 120 kN (old bearings) 3-4 Nm
Pinion rolling resistance, value on the spring balance (old bearings) 9-12 N
Backlash RBP735 gear ratio 3.67 0.25-0.33 mm
Backlash RBP735 gear ratio 3.93 and 4.22 0.20-0.28 mm
Backlash RBP835 gear ratio 3.96 and 5.14 0.30-0.41 mm
Backlash RBP835 gear ratio 4.27 and 4.85 0.25-0.33 mm
Input shaft bearing preload 0.20 mm

© Scania CV AB 2005, Sweden

08:05-02 79
 © Scania CV AB 2005, Sweden
80 08:05-02